AV wall mount break-out box with Keystone and Banana Jacks

thingiverse

I needed something to tame a mess of cables that were climbing out of a wall like some sea monster. Previously they had been going through a keystone panel with a bunch of custom knock outs which just looked ugly and did not thing for managing them. To get it under some control I made this box. It is a wall mount box for 6 keystone modules, and 16 banana jacks. There is also a cable pass through on the bottom for holding 5 thicker cables (intended for coax). Finally there is a hinged door with a latch that will hold the cover closed. The latch requires 2 springs of the type used in ball point pens. For more security there are also locations were M3 screws can be used to hold the door shut. I'm satisfied with the result, which is doing exactly what I wanted. There was one issue with a keystone RJ11 jack that I tried to re-use on this and it would not go into the opening for it. I found that my new Cat5E keystones fit perfectly however. The STEP file is uploaded for easy remixing. I used the Keystone Jack receiver model based on MWU's thing here: https://www.thingiverse.com/thing:548145 I also used pyr0ball's remix of MWU's model (converted MWU's model to STL), to help design this. I used Banana Jacks similar to these (I bought mine on Ebay): Update 8-18-2019 - I found that these look more similar to the ones I used. They have a tab for soldering the wires to: https://smile.amazon.com/DCFun-Connectors-Amplifier-Terminal-Binding/dp/B06XS43NTZ I think these may be better though since they don't use the tabs (which is a weak point): https://smile.amazon.com/gp/product/B07HH3XNYY This requires some M3 hardware: (5) M3 Nuts (5) M3x14mm screws (4) M3 brass inserts (these need to be 5mm or shorter) (2) M3x20mm (or longer) screws (12) female banana jacks similar to these: https://www.amazon.com/gp/product/B07HH3XNYY I printed the lid in a tall orientation and used the Cura support blocker feature to block supports on the small ledges where the latch locks need to clip into place. There is one on each latch and I added a pic showing the area on one of them. I also used tree supports on the lid and it worked well. I would also use support blockers on the cable management tie points if I were to print this again. Some of them were not usable due to some support material blocking the holes. The tie points should not need supports anyway. I used this PLA which matched up with the wall color very well: https://www.amazon.com/gp/product/B01H3IIBBQ/ I used shrinkwrap insulation on the connections to the banana jacks since they are in close proximity. I would strongly recommend insulating these connections to the banana jacks since they can rotate in the housing (they are not loose, but with enough force they can rotate). If the banana jacks rotate in the housing, the terminals could be brought in contact with each other. I may go back and add some glue around the terminals on the inside of the box to hopefully insure the jacks do not rotate. I recently found there is another type of banana jack connector which may work better which does not use a tab and instead the wire is soldered in coaxial with the connector: https://smile.amazon.com/gp/product/B07HH3XNYY <strong>So use this at your own risk, and feel free to remix it if you want.</strong> Parts are not oriented for printing.