(page 3)

Design and Construction (continued)

Now it's time to insert the other side of the power cord (the side with the molded strain relief) into the outlet box. First saw off the 1" hub entirely from the box. Saw flush to the box being careful not to scratch the side of the box. Use sandpaper to widen the hole, sufficiently so that the threaded section of the molded strain relief snugly fits through the opening and into the box. From within the box feed the four conductors through the metal tightening ring and screw the ring on to the molded strain relief, tightening and securing the cord onto the outlet box.

Secure the bare braided conductor (our partial shield) on to the ground screw of the outlet box. Next, cut off the factory fitted inserts from each conductor and strip off about 1" of the insulation from the same. Separate the strands of the live (red) conductor and twist them into a spade like shape (see picture above). Do the same for the neutral (black) conductor. These "spades" will be fed into the tightening screws of the Hubbell AC outlets, each in its appropriate section. If possible avoid directly touching the strands with your fingertips, use gloves or a piece of cloth as an intermediate layer while twisting. Apply Caig DeoxIT or similar solution on exposed strands of each conductor. Remove any extra liquid with a cloth.

Next we will connect the two AC outlets in serial configuration. Place the Double Outlet Cover Plate face down and place the Hubbell AC outlets face down on to the plate. The cover plate will act as a guide ensuring proper spacing between the two AC outlets. Using a pair of 12 AWG wires connect the live end of one outlet to the live end of the other outlet. This will bridge the outlets connecting the two hot ends (see picture above). Repeat the same for the neutral ends linking the neutral sides of the two outlets. I used two 12 AWG conductors (black color) for the live and two 12 AWG conductors (white color) for the neutral. Yes, the colors do not match those of the power cord but I had none in red so this had to do. Just keep track of what is what.

AC Outlet Center