"Wally" DIY wall box for electric vehicle
Description
This a project I have been working on for some time now: a 3D printed wallbox for charging our electric car. The goal was to keep the wallbox very compact, its outer dimensions are only 160mm x 160mm x 90mm The picture shows v1.0, which has been on duty for almost a year now. Printed in PLA in black and blue. The box consists of a fixed base part with all the electronics and wiring and a cover on top. The design takes a small DIN rail inside to accomodate all required parts - plus a fuse holder and a switch on the side. It is designed for a fixed type 2 charging cable. The plug holder/rest from the picture can be downloaded here: https://www.thingiverse.com/thing:2705321 and the EVSE DIN rail holder here https://www.thingiverse.com/thing:2723086 ** UPDATE 2021-03 ** The first wallbox is in service for 3 years now, still works like a charm. Upon request, here is a complete list of parts you need to finish this build: - EVSE board (or something similiar) with DIN rail holder (see above) - Contactor - suiting to your charge current - DIN mounting rail ("Hutschiene") 105mm (https://www.voelkner.de/products/3235752/Spelsberg-Normschiene-NS-35-106.html) - fuse holder 16mm diameter (https://www.voelkner.de/products/1009873/TRU-Components-TC-R3-54B-Sicherungshalter-Passend-fuer-Feinsicherung-5-x-20mm-6.3A-250-V-AC.html) - Switch (optional) for selecting the power output on the EVSE (https://www.voelkner.de/products/1009614/TRU-Components-TC-R13-405C-05-Kippschalter-250-V-AC-6A-2-x-Ein-Ein-rastend-1St..html) - M3x20 Screws for mounting the lid For those having problems finding this specific fuse holder or switch, I uploaded a base "v1.2 no switch no fuse". So you may skip out the switch and place a different fuse holder inside. I also added additional drill holes to suit different mounting hole patterns on the DIN rail. Have fun and stay safe!
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