edge molding
 

I am trying to fabricate a DC power outlet install that looks like this:

http://forums.pelicanparts.com/uploa...1274567089.jpg

it fits in a steel channel that has the acute angles shown (Upper rack or some such on a VW Vanagon Westphalia). I want to put something on it to space it out properly and make a nice neat installation.

The vinyl hose shown is one attempt, but maybe not the best. Rubber hose bends even worse than the vinyl hose.

Anybody got any ideas for what to use on the edge?

Thanks!

can you use something that doesn't need an edge, plastic that could be radius'd

Can you cut 45* angles for the tubing or try windlacing. Although you'll have to cut 45's for it as well.

Hardwood with a rabbet?

it needs to be flexible so wood is out

I checked on door protector moldings, but their interior is too narrow for this thing - it is about 1/8" thick.

I did a Gsearch on windlacing - the images seem to show that it is a sort of filled in tube so that won't work.

I did check on window molding but it all has an interior U channel that is too wide...

Foam backer rod is the first thing I thought of. I see you can get it open cell and closed cell. The latter might be water proof enough if this is an exterior mount. You can shape foam nicely with an angle grinder or even a bench grinder.

where I would get Foam backer rod in such a small size?

I need about1" OD, and all I see in the hardware stores is big stuff to insulate water pipes...

Randy, I've seen it in the door/window weatherstrip isle in about 1/2" size in coils. I know commercially it's available in bigger sizes for caulking tilt up concrete buildings.

A this point, maybe someone here has a scrap and can send it to you. I don't have any 1".

The other thing I thought of was stacking single electrical outlet exterior cover gaskets. They are rectangular and about the same size?

Thx, Milt - I'll look around town tomorrow.

If you check this thread you may find something helpful.

http://forums.pelicanparts.com/porsche-911-technical-forum/365628-911r-engine-lid-grill-material-6.html#post5283760

http://forums.pelicanparts.com/uploa...1271466031.jpg

RW, I have a few scraps of sheet plastic in three thicknesses, 1/8, 1/4 and 1/2 (actual). It's not brittle like styrene, it machines well with woodworking tools, you can router a nice edge onto it; if you stacked two pieces, one slightly smaller than the other you might have the setback and the reveal you are looking for - PM your address and the approximate size if this is something you think would maybe work.

http://forums.pelicanparts.com/uploa...1274670365.jpg

thx - I am looking for a 'quick' fix so I can take the buggy camping soon. I'll just stick with the plywood thing I have now - I can jam it in there and fix it up nicely later on if I have to.

I needed a specific type rubber edge/seal to protect and seal the gap between the tank and seat on my cafe bike. I ended up modifying a $2 rubber windshield wiper blade from kmart. Couldn't have come out better. Maybe you can do something similar.

you might try some vinyl edging like what's used in boats around compartment doors and lids. you might check a marine supply or boating store. maybe even a canvas/cover shop. it's about 3/8ths wide and 3/16ths thick. it will make a pretty sharp radius but you might have to cut the angles to fit what you need. just go pull a piece of a neighbor's bass boat. if you can't find it, I'could send you some. http://forums.pelicanparts.com/uploa...1274672595.jpg

Like this:
http://forums.pelicanparts.com/uploa...1274672855.jpg

here's another shot from the side next to a quarter for scale. it can be opened up to fit maybe 1/4" or better or squeezed tight for thinner. I believe it might be vinyl covered metal. close it tight and you have to pound it on. it's used on most aluminum boats built around here on just about every exposed sharp edge
http://forums.pelicanparts.com/uploa...1274673229.jpg