cardboard template

2 Articles

How To Design A Custom Generator Interlock Plate

February 22, 2021 by 84 Comments

If you connect a generator to your home’s main electrical panel when the power goes out, you need to make sure the main breaker is shut off. Otherwise, when the power comes back on, you (or the linemen) are going to have a bad time. There are commercial interlock plates which physically prevent the generator and main breakers from being switched on at the same time, but since they tend to be expensive, [HowToLou] decided to make one himself.

The hardest part of this project is designing the template. It needs to be carefully shaped so its resting position prevents the generator’s breaker from being switched on under normal circumstances, but once the main is turned off and out of the way, you should be able to lift it up and have the clearance to flip the lower breaker. Spending some quality time at the breaker box with tape and a few pieces of cardboard is going to be the easiest way of finding the proper shape.

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Cardboard Aided Design Is The New CAD

August 9, 2015 by 50 Comments

The term “workflow” gets thrown around a lot these days. For example, say you own a 3D printer and you just came up with an idea. The temptation is to go straight to your favorite CAD tool, start designing the finished product, and then hit print. That, in many cases, can be the worst thing you could do. You would be missing out on all the variation and design choices you can easily try out with a simple series of drawings.

So, you’ve worked out your drawing, played with the design a bit, and now it is time to design in 3D on the computer right?  Not so fast. Depending on the nature of the design, you might want to follow this nice tutorial from [Willy Nicholas] on how to quickly make a cardboard prototype.

Now, obviously this won’t work on all designs. But it’s a tool everyone should keep in their bag of tricks. It allows for basically free, quick mock ups that you can hold in your hand. That last bit is important, because having something you can touch and see is a huge part of the design process.

You can also use cardboard as an excellent device for making templates for working with materials such as sheet metal. In case you have seen it, check out “Project Binky” to see what a couple of blokes in England are able to accomplish with nothing much more than a welder, a grinder and some cardboard.