Exterior wiring through foam composite

headingwest

New member
Hi all,

Any ideas for wiring exterior items (eg lights) through foam composite panels?
Are there long waterproof grommets? Something to stop the wires rubbing? Also if I fill with silicon how do I replace faulty parts when the wires run through the shell?

Thanks for any ideas,

Jim.
 

Verkstad

Raggarkung
Firstly, dont use silicone for anything...

If its single pair of conductors and its penetration appears underneath a surface mount fixture. I suggest simply deburr or chamfer the openings and pass wire thru foam without sleeves or anything.
Use a re-enterable sealant such as butyl. Make provisions on the interior to allow slack wire to be pulled to exterior if needed.

My rooftop solar, its using cable what penetrates adjacent to one of the module mounting feet. That entrance is simply sealed with a neatly applied blob of urethane. The cable is basically unseen regardless, and secured against any movement.
Were those cables exiting high show, would use cable glands, cable clam, or similar mechanical compression seal.
 
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pugslyyy

Robinson Fuso
I wouldn't be super worried about vertical pass-throughs (i.e. walls), but for the roof (solar, antennas, etc) it makes sense to have as few holes as possible. I like to have a single hole with feeding multiple devices. As with a lot of things for overland, the marine industry is your friend for this.

 

Alloy

Active member
I wouldn't be super worried about vertical pass-throughs (i.e. walls), but for the roof (solar, antennas, etc) it makes sense to have as few holes as possible. I like to have a single hole with feeding multiple devices. As with a lot of things for overland, the marine industry is your friend for this.

Cable claims are great. I like to use them for multiple cables that may require the wires to be changed.

Edit....where the backside is no accessible the cable clam bolts will need to be drilled an tapped.

For single wires and cable like SOOW and 12VDC duplex I use a strain relief.


These come in straight and tappeerd ( NPT / pipe) thread. I like to use the tapered thread. One needs the right size (NPT) tap and I use a hole saw as twist drills tend to splinter the fiberglass. The threads and wire are sealed with black urethane.

Wires penetrating vertical walls need a drip loop.


If the wire isn't jacketed where it passes through the inside of the panel/wall I will drill a bigger hole to provide more clearance or wrap the wire to protect it from abrasion.
 
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