The quest for a project box is always a balance between cost, complexity, and style. We think [Pcmofo] really finds the mark with his exterior electrical box enclosures. He took the time to document his fabrication process for those that want to replicate his look.
These grey plastic boxes are meant to keep the elements away from home and commercial electrical systems. They’re easy to find and come in many different sizes (this one is 8″ square and 4″ deep). The plastic is very rigid, but still easy enough to work with simple tools.
[Pcmofo] starts by eyeballing the placement of his components. Once he has a good idea of where each should be located he grabs a caliper and uses Adobe Illustrator or Inkscape to design a template. This is attached with painter’s tape, and rough openings are made using a drill press. The holes are brought to the final size by hand using files for a nice finished edge. When it comes time to mount hardware, the plastic is strong enough to hold threads if you are careful when using the tap to cut them.
The example enclosure houses a temperature controller for fermenting beer. You can see some video of the enclosure embedded after the break.