Insteon In-LineLinc Mount for 4" Square Electrical Junction Box by joshuanapoli

Last crawled date: 3 years ago

Insteon In-LineLinc Dimmers are good for controlling built-in lighting in my home, but their installation leaves something to be desired. The device must be associated with another device (such as a light switch) using its SET button. But once the device is installed in an electrical box, the button is not available. The large size of the device can also make it hard to get a large enough junction box.
This bracket and cover are used to mount an 70x45x24mm In-LineLinc device in a 4" square electrical junction box. The cover has a window, so that the buttons can be safely accessed, without opening the electrical box. The cover extends the box by 15mm, holding the device mostly outside of the original electrical box volume. This makes it easier to pack the electrical box.
Materials
Taulman Alloy 910 works well for these parts. It holds self tapping plastic screws well. It is less flammable than ABS (UL 94 V2). Note that this cover will nevertheless be more flammable and have a lower melting temperature than a commercial UL-listed cover.
4" electrical box
8 screws: 6-19 x 0.500" or M3.63 x 12mm Pan Head Thread Forming Screw for Plastics. McMaster 99512A259 or 99397A682.
Tools
Drill
Torx T15 driver.
Right-angle ratcheting driver with T15 tip is useful depending on how the electrical box is mounted.
1/8" drill bit
17/64" drill bit
Instructions
Measure the distance between the side mounting screw holes on your 4" box. Some boxes have 1.250", others have 1.325", and some boxes have both. Print the correct device bracket and face-plate.
Drill the eight pilot holes of the bracket with a 1/8" bit. If necessary, clean out the screw head clearance hole on the face-plate with a 17/64" drill bit.
Mount the electrical box such that the side mount holes are accessible.
Complete all wiring within the electrical box, including the Insteon device.
Slide the Insteon device through the opening of the bracket. Use four screws to mount the bracket to the electrical box.
Position the device within the bracket and put the faceplate in place. Use four screws to secure the faceplate to the bracket.