CG1500 Single Level

The classic CG1500 enclosure gets a boost with our single deck mounting plate


Overview


Simple, sturdy, and customizable

So your new to the Christmas Light game, you ordered your CG1500 and when it arrives you scratch your head wondering how in the heck the power supply will mount. We've all been there, and the answer is simple - you buy a mounting plate. Now we have some really cool mounting plates for the CG1500 like our Standard Double Decker, or our Double Decker Full Size but maybe you are a purist, maybe you dont' have many components to mount, or maybe you don't like fancy things.

So here it is, the basic Single Level CG1500 mounting plate - Only ours is fully customizable using the JDeation Designer!


Features

  • Fully customizable component holes using the JDeation Designer
  • Perfectly matched to mount to a CG1500 Enclosure
  • ZipTie ports to secure wires to plate


Customize & Download our Featured Designs



Assembly Instructions


Assembly instructions for - CG1500 Single Level

Please read these instructions fully and carefully before beginning your assembly. A little bit of learning and planning can make the difference between a easy great assembly and a hard mistake prone assembly.

The following assembly instructions contain both design specific and general assembly instruction which may not be specific to your design.

1) Design Your Mounting Kit Hide

All of the JDeation designs are customizable using the JDeation Designer

View our detailed walkthrough video for instructions on how to use the JDeation Designer

2) Gather Required Hardware Hide

We offer Hardware kits which includes the parts below.

Our kits are cheaper than buying parts at home depot and contain exactly the parts you need.

HW Kit for CG1500 Single Level

* example image only
Buy Now - $4

The following pieces of hardware are required for assembly.

Most parts are available at home depot - all are available online.

  1. #6 x 1/2" Self Taping Screw - qty: 4
  2. 4-40 standoffs / screws for mounting components (PS, Controller, Power Dist, etc...)
  3. 4-40 locking nut
  4. Power Supply Screws - typically 4mm

3) Fabricate Mounting Plates Hide

We offer thick acrylic plates laser cut to your exact specifications.

Our 3/16 plates are much sturdier than using wood and come in multiple colors. Much easier and cooler than building your own.

3/16 Laser Cut Acrylic - CG1500 Single Level

* example image only
Buy Now - $12

The following plate fabrication instructions serve are general documentation for all mounting plate designs.


Step 0:

Acquire material to make your plates. Plastic or wood are good choices. The bellow instructions use 5mm plywood which was purchased from a local home depot. The material you choose MUST be 5mm or less in thickness.


Step 1:

Print your design on your home paper printer to scale.

On your design, click the download button and select PDF (Print). You must open the PDF in Adobe Reader to get the advanced print functions. Do not open the PDF in your browser. From the Adobe Reader print dialog box, select the following options.


Image of design printed to scale:

Step 2:

Cut and Tape your designs together. Use the Adobe cross marks to align paper perfectly. It is important to spend time on this step and get alignment correct as a misaligned tape job will interfere with hole placements on layout.


Step 3:

Apply Gluestick to back of paper. We have had good success with repositionable glue sticks.



Step 4:

Apply paper design to wood. Line up two edges of design with two edges of wood if possible to reduce cutting.


Step 5:

Drill the black circles on the design. The following size drill bits are recommended. Also while not necessary it is recommended to use a brad point drill bit as it allows greater precision due to its sharp point on tip.

Screw Size Drill Size Typical uses
4/40 1/8" Component standoffs
#6 5/32" Self tapping screws for mounting to enclosure
#8 3/16" 3" and 4" Bolts for P.S. and Shelves
#10 7/32" 6" Bolts for P.S. and Shelves

NOTE: All Black lines on design are cut or drill lines. Red lines are just for helping create the design and for information useful to assembly.



Step 6:

Use a Jig Saw to cut out the straight black lines.


4) Fabricate Power Supply Brackets Hide

The are 3 options for creating the necessary power supply brackets.

Note: If you purchase an acrylic plate through our store, it comes with all the necessary mounting brackets and you can skip this step.

Option 1: Purchase Acrylic Mounting Brackets

We cut 3/16 acrylic brackets which are very strong and are the best option

3/16 Acrylic Power Supply Bracket - x2


Buy Now - $1.50

3/16 Acrylic Vertical Power Supply Bracket


Buy Now - $1.50

Option 2: 3D Print the Brackets

The second best option is to 3D print your brackets. Download the STL designs from Thingiverse.

Download JDeation Mounting Bracket - Thingiverse


Option 3: Cut Mounting Brackets from Wood

Making from wood is a doable option but the small components make this the most difficult option. We recommend using a band saw with a fine tooth blade for these smaller parts.

The mounting bracket cutouts are included in the individual designs themselves.

5) General Double Decker Assembly Instructions Hide

The following assembly instructions are for the easy remove power supply design, but also currently serve as the general documentation for all other less complex builds. For general builds, please alter instructions by skipping unnecessary steps. The actual design shown is the MTMACR8-72 Easy Remove.



WARNING: DO NOT OVERTIGHTEN BOLTS AGAINST ACRYLIC - YOU CAN CRACK ACRYLIC. Nice and “screwdriver snug” is all you need.

Step 1:

Remove plastic or paper film from both sides of acrylic or wood. Its much easier to do this now than after assembly.

NOTE: Occasionally the fabrication process will remove one or both sides. If you can see through the acrylic clearly then the film is gone.


Step 2:

Attach the power supply brackets using 4mm screws and either horizontal or vertical mounting bracket.


Step 3:

Attach bolts. The MTMACR8-72 has both 4” inch and 3” bolts, but not all designs have both. These should be inserted in the largest holes on the plate. See diagram below for bolt / washer / nut ordering. NOTE: Refer to your online design to find appropriate holes.

WARNING: DO NOT OVERTIGHTEN


Step 4:

Attach 4/40 standoffs and k-nuts to smallest holes. No washer is needed.

WARNING: DO NOT OVERTIGHTEN


Step 5:

Attach components to the standoff. No washer is needed.


Step 6:

Use self tapping screws to attach mounting plate to the enclosure. Holes should be medium size and in each corner of the mounting plate.


Step 7:

Insert power supplies. See diagram below for spacer / nut ordering. You control the distance between the power supplies through how long you make your spacer. The spacers are held in place with a K-Nut. No washers needed.


Step 8:

Insert upper shelf. Upper shelf sits directly on spacer and is attached with a K-Nut from the top. No washer is needed.

Step 9:

Wire it up and make it fancy.

Few tips:
  • Don’t tin your wires if inserting them into a screw down clamp. Solder will expand slightly and loosen the clamp.
  • Use fuse between power supplies and controllers. A lose connection could cause an arc and if unfused could damage your power supply or your controller and potentially cause a fire.
  • Make sure you use appropriate guage wire for the amperage you plan on needing. Small guage wire on high loads can cause greater voltage loss and in extreme cases start a fire.

Step 10:

Post a picture of your killer new build to facebook - make sure you tag JDeation Designer!

Use our contact page if you require assistance with your build. This is a new service and we would love your feedback. What worked well, what didn’t work well?

Finished Build (outside of case)

Finished Build with wood plates (outside of case)