Summary

I purchased this power supply: ABI 24V 500W Power Supply Indoor Outdoor LED Driver Rainproof Weatherproof 21A
https://www.amazon.com/ABI-Supply-Outdoor-Rainproof-Weatherproof/dp/B01IU8QBCO/ref=lp_17579358011_1_16?srs=17579358011&ie=UTF8&qid=1531079981&sr=8-16

I wanted a terminal cover with a power plug, on/off switch, and 3 XT60 connectors. I didn't find one on Thingiverse for this PSU, so i designed one in Fusion 360.

I used this socket: HONGYETAJA Inlet Male Power Socket with Fuse Switch 10A 250V 3 Pin IEC320 C14
https://www.amazon.com/gp/product/B01LYMNQ2L/ref=oh_aui_search_detailpage?ie=UTF8&psc=1

Fusion file is below. You should be able to view and download.
https://a360.co/2m0SdDr

Printing

• Prusa I3 MK3.
• AMZ3D PLA - neon-yellow.
• 0.3mm Layer height.
• Three top and bottom layers.
• Three perimeter lines.
• No supports.
• 25% infill.
• 210c nozzle and 60c bed.

Assembly

I used 16 gauge wire on the XT60 connectors, since they could carry up to 24 amps of current. I soldered the wires on to the sockets, and added heat-shrink, before gluing them to the cover.

The photos show 24 gauge wire on the 120V side of the socket. I should have used a thicker wire, like 18 or 16.

I used Gorilla Glue to set the XT60 connectors and the socket to the PLA. I tried super glue, but it just broke after a few insertions/removals. The Gorilla glue is an expanding glue, so only use a little. I used a hobby knife to scrape the excess glue, before it fully hardened.

On the power supply, remove the 4 screws that hold the metal plate over the terminal strip. Remove the plate. Put the cover over the end of the supply, and use the same 4 screws to attach them together.

Improvements

• I should have used thicker gauge wire on the 120V side. 18 or 16 AWG wire would be better. Those short lengths of wire should be able to handle 4 amps, but the electronic technician in me says "better safe than smoked".
• Perhaps the socket should have been rotated 180 - putting the switch on the outside, and the C14 plug on the inside.

Credits

I used beefinator's Cover Plate for inspiration, and to get the dimensions of the XT60 hole.
https://www.thingiverse.com/thing:132022

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