Carlon Meshtastic Mounting Solution

UPDATED (10-17-2025) v6 DESIGN

This a modular mounting system for the Carlon 4x4x2" electrical enclosure, found at most Home Depot locations in North America: 

USA:
https://www.homedepot.com/p/Carlon-4-in-x-4-in-x-2-in-Gray-PVC-Junction-Box-E989NNJ-CAR/100404097

Canada:
https://www.homedepot.ca/product/carlon-nonmetallic-junction-box-4-in-x-4-in-x-2-in-/1000403714
 
There are some great printed enclosures out there, but their permeability isn’t guaranteed protection from weather and ingress. I required these nodes to work inaccessible at altitudes above 8000 feet in The Rockies, for up to 6 months at a time. 
 

This Carlon enclosure is NEMA Type 4/4X/6P rated:

https://carlonsales.com/techinfo/brochures/conduit/Junction_Boxes_Brochure.pdf

I would highly recommend to use at least PETG, ASA or ABS if it's going to be outside and subject to direct sun or freezing temperatures. (We have tested long term outdoors with PLA… for science… and it will eventually fail at high stress points).

It was designed for creating simple weatherproof Meshtastic solar repeater nodes. The carrier plates make it possible to mount a RAK Wireless Wisblock RAK19007 and other items (it will also fit the older RAK5005 model). While you can just pair it with a regular 5v panel (like the Soshine 6W and the Voltaic Enclosures 3D printed mount) and standard lithium batteries.It was designed for creating simple weatherproof Meshtastic solar repeater nodes. The carrier plates make it possible to mount a RAK Wireless Wisblock RAK19007 and other items (it will also fit the older RAK5005 model). While you can just pair it with a regular 5v panel (like the Soshine 6W and the Voltaic Enclosures 3D printed mount) and standard lithium batteries.

NOTE: For concerns on solar charging lithium batteries in cold weather, please refer to our article here.

HARDWARE REQUIRED:

3M Double Sided Tape

3 x M2.5 x 6mm bolts for each carrier plate

4 x M2.5 x 6mm bolts for the Wisblock board (or the M2.5 mounting bolts that came with them)

(optional) 4 x M2.5 x 6mm for the Waveshare board 

(optional) 4 x M2.5 x 12mm for the Voltaic Enclosures boards (if using both the MPPT and regulator boards stacked) or 4 x M2.5 x 6mm if just using the Voltaic Enclosures MPPT board by itself.

BASEPLATE MOUNT UPDATE (Oct 2025):

Drilling and Machine screws are no longer requires. Simply use 3M double-sided tape to mount the new v6 baseplate design to the bottom of the Carlon enclosure.

POLE MOUNTING (option 1):

To pole-mount the enclosure, you will need to drill out the four mounting “ears” on the enclosure with a ¼" drill bit, so as to accommodate these sized u-bolts (M6 x 50mm x 80mm):

Canada:
https://www.amazon.ca/uxcell-Round-U-Bolt-Length-Washer/dp/B093SR345L

USA:
https://www.amazon.com/uxcell-Round-U-Bolt-Length-Washer/dp/B093SR345L
 

I've included a u-bolt saddle with these files to provide better hold on smaller poles around 35mm diameter, or can use the one designed for larger 5mm diameters here:

https://www.printables.com/model/819151-u-bolt-saddle-m6x50mmhttps://www.printables.com/model/819151-u-bolt-saddle-m6x50mm

POLE MOUNTING (option 2):

Use the Carlon Specific brackets from Lead:

https://www.printables.com/model/1279998-leads-carlon-enclosure-bracket-with-velcro-optionhttps://www.printables.com/model/1279998-leads-carlon-enclosure-bracket-with-velcro-option

These can use u-bolts (the ones specified by Lead), velcro straps, or hose clamps and will bolt to the Carlon mounting ears without any drill modification.

SOLAR PANEL MOUNT v6:

Although we've listed the solar solutions from Voltaic Enclosures to mount 6w Soshine and 3w MiniRenogy panels we now have an alternate mounting solution. The Carlon Enclosure Solar Mount brackets (left and right) will allow you to directly bolt on the Soshine 6w panel with the Voltaic Enclosures panel brackets, or 3w MiniRenogy panel with our panel adapter brackets.

We have now included brackets to mount a solar panel directly to the Carlon Enclosure itself with no drilling modification. Note that this will require you to use the Pole Mounting Option 2 from Lead (linked above) since the u-bolt mounting option will not work well (at least not yet until we update the design).

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OLD v5 INSTRUCTIONS:

Recommended Tools:

• 2mm HEX drill bit with HEX bit screwdriver
• ¼" drill bit (for pole mounting) and drill
• Screwdriver for M2.5 bolts/screwsRecommended Tools:

The base plate is mounted to the bottom of the enclosure by CAREFULLY using a 2mm drill bit by hand (a hex drill-bit with a screwdriver would be ideal) to tap 4 pilot holes (according to plate holes at the 4 corners) just deep enough to not penetrate the other side. If done slowly you can see the white stress point on the other/outside just start to appear, which is perfect. You can then screw in 4 x M2.5x6mm bolts and they will self tap themselves. 

¼" to 3/8" length wood screws may also work, but aren't consistent in how they tap the plastic.

The carrier plates require 3 x 6mm length M2.5 bolts for mounting them to the base plate , and 4 x 6mm length M2.5 to mount the RAK and Waveshare boards to the carrier plates (4mm will also work for all of the above, which are the same that come with the Wisblock)

There are also the following MPPT options:

1. The Waveshare (D) model MPPT (for 6v or higher Solar Panels):
   
   https://www.waveshare.com/solar-power-manager-d.htm
   
    
2. The LTO battery (HIGHLY recommended for cold weather) and MPPT Solar Charge kit from Voltaic Enclosures (NOTE: the carrier plate is just for the boards, and will still need spacers and m2.5-12mm bolts if you stack them):
   
   https://www.etsy.com/ca/listing/1616711365/lithium-titanate-oxide-batteries-lto?

The LTO MPPT from Voltaic Enclosures will require a bit of extra hardware if you choose to stack it with the regulator board (see above).