Repair to cover hole in wall left by removing solar controler. Need advice

[Yoda]

Something I have never done on an RV is repair a hole. Cut a lot of them, but never patched one. I want it to look good - not look like a patch.

What am I up to you ask??

I am installing a BMV 712 and removing a Go Power PWM-30 solar controller from the wall for a place to put it. I am replacing the PWM with a MPPT solar controller Decided to keep the undersized Victron unit to replace the PWM one that is not Lithium compatible. I want to and use the hole for BMV 712 but hole is way oversized. Long story other posts elsewhere.

The controller face plate is 4.25" by 7.48" or 108mm by 190mm for our northern friends. the cut out is about 1/2" smaller, but I need to cover the existing screw holes that are at the edge of the face plate. Now to go back in the hole I am wanting to mount the BMV 712. Its 2" in diameter. It came with an optional cover plate that 2.58" square. So I need something strong enough to hold the BMV unit that will cover the hole and look good. Now I can build almost anything out of wood, just not this small and delicate. Besides I want it to look good and I don't think a piece of 1/4 in ply would look good, even painted or stained.

I had thought about black plexiglass, but you can see through it? Maybe paint the back? However I have never worked with the stuff nor do I know where to get it. I know it scratches easily too. Steel or aluminum plate? Don't really have the tools. Any help is appreciated.

Question - Is there a source out there that can make the plate up with the hole in it? Not having much luck searching, but I really don't know what to call it.



The controller I am removing and where the plate would go is on the back wall by the stairs below the T-stat and above light switch. Dealer put the existing solar controller there as wires can easily run from the roof to the basement through this wall beside the vent stack which runs vertical. Its about where the edge of the mirror is.

Thanks for any help

Keith

[howson]

Yoda

I'd get a piece of nice wood and cut to the right size to cover the existing hole with a little extra. Router the edges with SWMBO's desired pattern, and stain to match the interior. The BMV, of course, mounts in the middle of the new panel. The panel then gets mounted on the wall over the existing hole.

Howard

[Yoda]

Yoda

I'd get a piece of nice wood and cut to the right size to cover the existing hole with a little extra. Router the edges with SWMBO's desired pattern, and stain to match the interior. The BMV, of course, mounts in the middle of the new panel. The panel then gets mounted on the wall over the existing hole.

Howard

I had not thought of staining to match the interior. That might work. Would need to find some 1/4 furniture grade ply. Or could plane down some solid hardwood too. Dont want it cracking. Ill check withe local custom cabinet shops. Maybe they have a scrap piece available.

Thanks

[Guest]

Keith,

Plexiglas can be purchased at any glass shop, and they can bevel it. And you can paint the back to prevent seeing through it. It looks like an attractive cover plate of wood, Plexiglas or other material would be the best route.

Jim

[Yoda]

Keith,

Plexiglas can be purchased at any glass shop, and they can bevel it. And you can paint the back to prevent seeing through it. It looks like an attractive cover plate of wood, Plexiglas or other material would be the best route.

Jim

I got lucky. local metal shop is making up a 16 gauge aluminum plate, complete with holes $15. Just need to sand and paint. Caught him at the right time. Its already done - just need the snow to stop so I can pick up. What paint is good for aluminum?

Thanks everyone

[Country Campers]

It is not really the paint it is the primer and the pre painting steps. I believe that there is a special primer for Aluminum. You will have to ruff up the surface to get good adhesion. I have seen paint fall right of after a while with out using the proper items ( do not ask me why I know this).

Anodize is the best method for aluminum but can be expensive for one part.

Brian

[Yoda]

It is not really the paint it is the primer and the pre painting steps. I believe that there is a special primer for Aluminum. You will have to ruff up the surface to get good adhesion. I have seen paint fall right of after a while with out using the proper items ( do not ask me why I know this).

Anodize is the best method for aluminum but can be expensive for one part.

Brian

Thanks Brian
He was going to have prep instruction there tomorrow when I go to pick it up. He was running it through their washer tonight with a bunch of other parts he was making for someone.

[ncitro]

You’re already set but my suggestion was going to be to have something made up (wood or metal) to house everything that’s on the wall. Pull them all off and remount them all to make them nice and pretty. That’s what I did.

[Tommyp]

Powder coat it black. Last a long time. Or any other color you choose.

[Yoda]

Powder coat it black. Last a long time. Or any other color you choose.

Thanks
Ill look into that tomorrow, Durango is a small place, but I think there is at least one place to check on.

[Yoda]

Powder coat it black. Last a long time. Or any other color you choose.

Found a place to powder coat. Does $25 sound about right?

[Country Campers]

Found a place to powder coat. Does $25 sound about right?

As long as it holds. Painting would be cheaper though.

Brian

[Yoda]

As long as it holds. Painting would be cheaper though.

Brian

That's the big question - getting paint to stick to aluminum. The powder coat folks sandblast and treat the aluminum then powder coat. Folks said their process eliminates any chance of paint separation. Besides - like my typing skills, my painting skills are much worse

[Yoda]

As long as it holds. Painting would be cheaper though.

Brian

Today was a good day. Cal steel in Durango gave me a very wrong estimate. Instead of $15 it was $8.75. Now this was for a 4.5" by 7.75" piece of 16 gauge aluminum with a 2" center hole and 1/8 inch holes in the corners for mounting. All edges were smoothed over too. I was charged $3.58 for materials and a whopping $5 for labor. From the marks on the plate he did it old school. No CNC work here. I asked about painting and they said to take it to Evolution Powder Coating. Its a little shop hidden in the back of SKA fabricating. They too overestimated their price. Instead or $25 they will be doing it for $20. Found a very durable 10% gloss flat black coating. Should be done next week as they use that same color a lot. Lesson learned SHOP LOCAL Other prices I had gotten on the net were over $100 - one about $180 (Engineer and CNC time). Ill post a picture of the finished plate when done. BTW that $20 includes the sand blasting prep and everything. America still has honest shops and they have earned my business.

Should be done next week sometime.

Thanks everyone for the ideas
Keith

[Country Campers]

Today was a good day. Cal steel in Durango gave me a very wrong estimate. Instead of $15 it was $8.75. Now this was for a 4.5" by 7.75" piece of 16 gauge aluminum with a 2" center hole and 1/8 inch holes in the corners for mounting. All edges were smoothed over too. I was charged $3.58 for materials and a whopping $5 for labor. From the marks on the plate he did it old school. No CNC work here. I asked about painting and they said to take it to Evolution Powder Coating. Its a little shop hidden in the back of SKA fabricating. They too overestimated their price. Instead or $25 they will be doing it for $20. Found a very durable 10% gloss flat black coating. Should be done next week as they use that same color a lot. Lesson learned SHOP LOCAL Other prices I had gotten on the net were over $100 - one about $180 (Engineer and CNC time). Ill post a picture of the finished plate when done. BTW that $20 includes the sand blasting prep and everything. America still has honest shops and they have earned my business.

Should be done next week sometime.

Thanks everyone for the ideas
Keith

It is always good to find a local shop that is willing to help an individual out. A lot of shops will not do this.

Brian