Recessed old work box for AC Infinity Controller 69

WORK IN PROGRESS

• The magnets aren't needed and replacing the backplate with small corner protrusions would simplify printing substantially

Fully recessed old work box for the AC Infinity 69 controller that allows the unit to be flush mounted in a wall. Fits in a normal 3-½" stud bay.

This model has the controller protrude 6.4mm so that a faceplate can be added and it will be flush with the faceplate. No part of the model should be visible once installed with a faceplate and the faceplate retains the controller so it cannot be removed.

The original model this was remixed from has the entire controller protruding off the wall, the controller is 1 inch thick so this is substantial in a finished area.

Just like the original, separate flipper parts are required to make this work along with magnets and screws for the flippers. I harvested flippers from a mass produced old work box rather than print them. The faceplate takes standard 6-32 nylon slotted oval head wall plate screws.

This model is best printed on it's back with supports. I'm using zigzag supports at 30% support density. Gradual support infill steps can really help cut down on wasted filament and print time.

Box printed in PETG, faceplate in Nylon.

• Added a recess so the entire controller can be inside the wall, intended to be used with the separate faceplate included in the model. 
• Added threaded holes to the flange in order to accept 6-32 screws for a faceplate. 
• Standoffs are placed on the bottom for a tight fit, these are much easier to adjust than changing the dimensions of the box itself.
• Added a backing plate to give something to attach the magnets to. In the original model the magnets would be against the wall.
• Thicker rails for the flippers so they don't break off while tightening
• Text on the mounting face for confused electricians in the future
• Rounded edges to make fitment easier, add some strength, and reduce overhangs.