I needed to redo my power inlet on my boat, and I decided to use a smartplug. I'd like advice/oppinion if what I did will work, or cause me some griefe later.
Even though they use the same hole-size, the smartplug inlet has a flat fitting part on the hinge that is taller than the Marinco I had, and so it would not fit flush with a small lip I had on the boat. There was also a cable inlet that I am not planning on needing, and both had a fair amount of rust at the screw holes so I cut out the whole thing and re-welded in a new plate.<a href="http://ontheboat.net/gallery3/index.php/photos/4457"><img src="http://ontheboat.net/gallery3/var/resizes/Oceana/projects/Electrical/AC/IMG_20120215_125650.jpg?m=1330429257"></a>
I painted the whole thing with pettit rustlok primer.
Several days later, I cut into it with a hole saw using WD40 as a cutting fluid:
<a href="http://ontheboat.net/gallery3/index.php/photos/4799"><img src="http://ontheboat.net/gallery3/var/resizes/Oceana/projects/Electrical/AC/Smart-Plug-power-inlet/P3271094.jpg?m=1332908672"></a>
I didn't get very far til I ran out of battery
power, but it seemed to work well-enough.<a href="http://ontheboat.net/gallery3/index.php/photos/4800"><img src="http://ontheboat.net/gallery3/var/resizes/Oceana/projects/Electrical/AC/Smart-Plug-power-inlet/P3271095.jpg?m=1332908717"></a>
So here's the part I'm a little unsure of, I drilled and tapped pretty small holes for the 8/32 screws to hold it in. It was raining pretty hard at the end f the day and I didn't think I could apply primer, so I sprayed the raw edges with wd40 and covered it with the plug
.<a href="http://ontheboat.net/gallery3/index.php/photos/4818"><img src="http://ontheboat.net/gallery3/var/resizes/Oceana/projects/Electrical/AC/Smart-Plug-power-inlet/IMG_20120328_102411.jpg?m=1333008169"></a>
In retrospect I should have probably applied ospho instead and let it dry.
The next day, I tried to clean off the WD with acetone, then when I put in the screws I put a bit of butyl around the underside of the screw heads and tef-gel on the hole threads.
Does that Seem reasonable? I'm worried about water
weeping through the screws, through the rubber gasket
to the threads (and then rust starting.) Should I have put teflon tape or like 3m 4000 on the threads?
I'll need to pull it back off later to fair and paint
it, but the end result is pretty nice: <a href="http://ontheboat.net/gallery3/index.php/photos/4820"><img src="http://ontheboat.net/gallery3/var/thumbs/Oceana/projects/Electrical/AC/Smart-Plug-power-inlet/IMG_20120328_151216.jpg?m=1333008187"></a>