Control Panel Backboard Options

[skerekes]

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Caught the bug to convert my gas fired Brutus 10 style brewery to electric so I can brew in my air conditioned shop. I've been in planning mode for a few weeks and I'm starting to purchase components (Huge thanks to Kal for making this process easier).

When I built my shop I installed a 28" Leviton Structured Media Enclosure (w/hinged door) with intentions of housing my BCS controller and various other electronics in there. With my new quest for electric, I'm thinking about repurposing that enclosure as my control panel for a clean in-the-wall look (plus, it's already there). It is far enough from kettles and other liquids, so I'm not too concerned about NEMA/IP ratings, as far as liquids go. I plan to install the heatsink and SSRs (along with the rest of the normal indicators and knobs) in the vented door and install a backboard inside for the rest of the components, being careful about layout since the enclosure is only 4" deep. I may add a couple of small fans for airflow if needed.

My questions are around what materials I can use for the backboard. Since the enclosure is not a standard size and Leviton doesn't make a backboard option for it, I need to make something or have something made. I have a piece of clear 1/4" polycarbonate sheeting that I can easily cut with my table saw, but wasn't sure if there would be issues with that (thermally, electrically or otherwise). I believe I could still drill and tap that material without issue (just can't crank screws down crazy tight) and it would be free. My other option is going to a local machine shop and having a piece of sheet metal cut to the appropriate size. If I have to go that route, what gauge/thickness would I need to go with and should I get it powder coated or would standard spray paint be sufficient?

[kal]

I'd probably go with metal. What thickness I'm not sure, but something thick enough such that it doesn't bend on its own at all. You want zero flex as you don't want it to bend at all. I'd do some research into what sort of thickness is usually used for control panel backplates and go with that. Make sure to have enough mount points too (depending on size).

You don't have to paint it.

Welcome to the forum!

Kal

[kal]

I'd probably go with metal. What thickness I'm not sure, but something thick enough such that it doesn't bend on its own at all. You want zero flex as you don't want it to bend at all. I'd do some research into what sort of thickness is usually used for control panel backplates and go with that. Make sure to have enough mount points too (depending on size).

You don't have to paint it.

Welcome to the forum!

Kal