If you’ve been reading all my posts, you know that I had to rewire my garage outlets so that at least one of them would remain active all the time.
Here’s the finished wiring, with plenty of wires stuffed into a box and a box extension. The cover plate is not attached in this picture—otherwise, it would be pretty dull.
Things you probably don’t need to know
The National Electrical Code limits the number of things you can squeeze into an electrical box—based on the size of the box, the size of the wires, and devices you need—like the duplex outlet above (right). This is to protect the wires from damage and to prevent overheating.
- First, you need to know the volume (in cubic inches) of the box. In my case, the two boxes’ total volume is 60.6 cubic inches. Each 12-gauge wire counts as 2.25 cubic inches.
- I have 15 conductors for a total of 33.75 cubic inches. Then there’s the duplex outlet. It counts as two conductors, for a total or 38.5 cubic inches.
- If you’re keeping track, you see that I’m well under the allowable 60.6 cubic inches. But if you take a look at the photo you’ll wonder how more stuff could be squeezed into the box.
If you simply don’t have a life and want to learn more, check out this excellent site:
Electrical box fill requirements
Dammit!
After verifying that the door really operates with or without the lights, I noticed this troubling thing. If you’re saying to yourself, “That looks like a broken hinge,” you’re exactly right.
This is the center hinge. There are three of them, and all three were damaged. I’ll say right now that it’s my own fault, but I want those terrible instructions to take part of the blame.
I installed them backwards. When they’re installed backwards, here’s what happens:
Why don’t you rewrite the instructions?
I called the manufacturer. The technician knew the problem before I finished my sentence. It’s apparently a very common mistake due to some confusing words and pictures in the instructions.
She’s sending four new hinges (free, of course). I’m not supposed to operate the door until they’re installed. Sounds like another dare, doesn’t it?
I removed the broken hinges, straightened them, clamped them in a vise, welded them back together, then reinstalled them. The door is once again operating while I wait for the new hardware. Ha!
Next: More siding, trim, and thoughts about a regular door
*This famous line from Robert Burns’ poem: To a Mouse, on Turning Her Up in Her Nest with the Plough, describes how man’s plans often don’t work out. It also describes how humans think about the past and future and worry, while a mouse lives only in the present.
Read the entire poem in its original form with its standard English translation here:
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