Electrical Knockout Fillers / Plugs - 1/2" to 2"

Fully parametric knockout fillers with options for o-rings, TPU gasket, DIY or no gasket. Threaded for 3/8-UNC.
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updated September 7, 2023

Description

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Options provided for ½", ¾", 1", 1-¼", 1-½", 2" knockout holes. Simple prints that thread together perfectly, use the included nut, thumbwheel, or use your own 3/8-UNC nuts.

Dimensions:

  • These are sized for standard KO's, but all dimensions are parameterized and available in the included Fusion 360 archive file.
  • Threads are 3/8-16 UNC (Class 1 Clearance) with an additional 2.5 thou removed on every thread face on the stud and nut (total 5 thou if using provided printed nuts). At these dimensions threads run smoothly and the stud attachment fails before the threads do.
  • O-ring seats are sized for 25% compression (although the stud will fail before the o-rings are fully compressed).
KO Nominal SizeActual Hole SizeO-Ring (AS568)Overall Filler OD
½"0.875"-2141.325"
¾"1.115"-2191.637"
1"1.362"-2231.950"
1 - ¼"1.701"-2262.325"
1 - ½"1.951"-2292.700"
2"2.416"-2333.137"

Special Instructions:

  • Prints well with 0.40mm nozzle @ 0.2mm layer height, 15% infill. If you need a tighter seal, print at 100% infill so the stud is stronger and you can tighten it further.
  • If you need the best possible seal, consider using RTV silicone or easily compressible foam. The TPU & Nitrile gaskets do compress and seal (as-tested), but cannot be tightly compressed without the printed stud failing.

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The author marked this model as their own original creation.

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