This model is a outdoor enclosure for a Kia Niro PHEX 115v charger. It may not apply to other PHEV vehicles, but there could be aspects you can re-use or adapt for use with your vehicle. I intended this to be printed in ABS for outside use, but my PLA prototype has been holding up well for 6 months now! Let me know if you print one in a more robust material! I increased the density to 30% for most all parts. The exception was the latching mechanism that I increased to 80% for strength. Tree Supports were used throughout.

There are three basic assemblies:

1) The holder or spool used to wrap the charging cable around: My printer is only 220x220, so its printer in two parts - 'Cable Holder Left' and Cable Holder Right' The will snap together, but use CA glue to fix them properly

2) The inner case - this holds the charger itself, which in turn will be placed in the outside enclosure. NOTE: I lost the original STL for the inner case. The one I included here should work just fine, but full disclosure - I haven't printed this one myself. If there's an issue with it, please let me know! Print 'Inner Case' and 'Inner Case Lid'. They should encapsulate the charger and snap together.

3) The outer case: This one is a little tricky! To start:

a) print the 'Base Segment Left' and 'Base Segment Right'

b) print 2x 'support pin' and 4x 'Secure Pin'.

c) To assemble, slide 2 secure pins into 'Base Segment Left' and two into 'Base Segment Right'. All should slide freely, Note the upper portion of the secure pins should point outward (see pngs)

Now insert and glue into place the two support pins into either base segment, and then glue the two base segments together.

d) Now print out the 'Lock Button', 'Lock Catch Pin' and the 'Lock Latch'. Use CA glue to affix the 'Lock Latch Pin' into the upper right corner of the base. Refer to the snapshot images for placement. Note that all the latch parts I printed in blue to make them easy to spot! See the 'Lock Latch' and the 'Lock Button' aside for now. They'll be assembled with the 'Outside Charger Cover'

e) Now print 'Charger Cover Left' and 'Charger Cover Right. Both should snap together, but affix the two halves with CA glue.

f) Now insert the 'Lock Button' through the hole provided one the Changer Cover (outside) and affix the 'Lock Latch' on

the inside with CA glue. Ensure the assembly can rotate freely.

Finally, you're ready for the final assembly.

1) Use the provided holes in the base segments to mount it on your outside wall (don't overtighten!). Spread the changer cover open a bit (don't crack it!) and pop the pins into the provided holes. At this point you should be able to open, close and latch the external cover.

2) Slide the 4 'Secure Pins' on the base to the inside. Place your charger in the inner case and snap on the lid. Now place you inner case and charger into the enclosure and secure by sliding the 'Secure Pins' into place.

3) Mount the spool below to wrap up your changing cable and you're good to go!

Happy charging!

Niro PHEV Outdoor Charging Enclosure

0.2mm layer, 2 walls, 15% infill