DIY Temperature Control W/Dimmer Switch (WARNING PIC HEAVY)

Here is a little writeup I decided to do on building a device to control temperature using a standard dimmer switch and a few more parts available at any General store for a little under $20. And while some may say that a thermostat is not much more than that. I like the design and would like to share it among friends. I am an electrician by trade so I will do my best to explain the process and hopefully not embarrass the elders to badly.


First here is the list of supply's that I used to build this:

http://i1022.photobucket.com/albums/...psb4f0ba4e.jpg

1. Dimmer switch (I picked mine up at Wallyworld for $5)

2. Replacement cord (also obtained at wally world for around $5)

3. Metal box with outlet & switch cover (picked up at lowes for around $7)

4. Outlet (I prefer the nicer ones that squeeze the wires rather than wrap around)

5. Service cord clamp (around 40 cents at lowes)


List of tools needed to build this:

http://i1022.photobucket.com/albums/...pscbf5707f.jpg
1. Pair of wire strippers

2. Side Cutters (optional)

3. Needle nose pliers

4. Electrical tape

5. Multi screwdriver



Step 1: First thing I did was trimmed down the mounting brackets on the outlet to fit the box a little more conservatively. I used my orange side cutters. It should look a little something like this.

http://i1022.photobucket.com/albums/...ps29bbc12d.jpg




Step 2: Screw the outlet in place on the cover as shown in the pics below. The outlet should now fit in the cover without being to snug if trimmed correctly.

http://i1022.photobucket.com/albums/...ps7911a819.jpg

http://i1022.photobucket.com/albums/...ps9834a458.jpg




Step 3: Open the dimmer switch package, it will need trimming down as well (again I used the side cutters). Trim the dimmer mounting bracket as shown. It will take a little trail and error to fit it in with the outlet, just don't go too much at once. I ended up trimming a little bit off all 4 sides.

http://i1022.photobucket.com/albums/...psfad7a515.jpg

http://i1022.photobucket.com/albums/...psc5ccf538.jpg

http://i1022.photobucket.com/albums/...ps9f957975.jpg





Step 4: Once it fits fairly tight but not cramped, screw the screws in and make sure everything fits. Don't go to crazy the dimmer needs to be removed in order to wire the outlet. At this point it should look like this.

http://i1022.photobucket.com/albums/...psad1aa2ae.jpg





Step 5: Now lets move on to running the service cord through the box. Knock one of the small 1/2 knockouts out with your pliers (I used the middle one). Then install the service cord clamp into the hole and tighten it down with your screwdriver and pliers.

http://i1022.photobucket.com/albums/...ps284cc3ef.jpg

http://i1022.photobucket.com/albums/...ps1115a14b.jpg

http://i1022.photobucket.com/albums/...ps8a546bfb.jpg




Step 6: Run the service cord through about 6 inches and tighten the 2 screws on the sides down to clamp the cord in place. Once that is done strip the black insulation off down to about an inch leaving only the insulation on the black & white wire.

http://i1022.photobucket.com/albums/...ps6579834f.jpg

http://i1022.photobucket.com/albums/...pseaa709b9.jpg




Step 7: Once you have test everything and it all screws in no problems, your ready to wire it up. Remove the dimmer from the cover (the outlet can stay in). Attach the green wire from the dimmer to the ground terminal on the outlet, then wire the white (neutral) wire from the service cord to the silver terminal on the outlet. Silver is always neutral on the outlet, if your still unsure flip it over. The longer prong is neutral. Next wire one of the black wires from the dimmer to the load side (gold terminal) of the outlet. Should stop and mention here that I always use the clamp style outlets with stranded wire as it holds better and keeps the wire from fraying which on a metal box would be bad if one of the strands grounds the side of the box. Lastly wire the only other black wire on the dimmer to the line (black wire) coming off the service cord. Here's what it should look like completed.

http://i1022.photobucket.com/albums/...ps0097e66b.jpg

http://i1022.photobucket.com/albums/...ps6beb35ed.jpg

http://i1022.photobucket.com/albums/...ps6510bd60.jpg

http://i1022.photobucket.com/albums/...ps0f57d455.jpg




Step 8: Tape everything up & check then recheck to make sure no wires are touching where they shouldn't be. At this point go ahead and reinstall the dimmer back into the cover.

http://i1022.photobucket.com/albums/...ps7ebd50ba.jpg




Step 9: Carefully place the cover onto the box taking care not to pinch any wires. Install the 2 screws that hold the cover onto the box.

http://i1022.photobucket.com/albums/...ps9074b07b.jpg






And here's the finished project!

http://i1022.photobucket.com/albums/...ps58957159.jpg

http://i1022.photobucket.com/albums/...ps182cd28c.jpg


I have used these in the past with great success! I know I suck at doing these, I'm sure I'll probably come back multiple times and add stuff I forgot to mention. Just wanted to share with the crew of awesome people on this forum my method for regulating Heat. Peace :D:D

Nice write up!

I love the design, it looks slick, but I'm just wondering, is there any advantage to this over a basic lamp dimmer (under $10), or is it just a nicer appearance?

Curious why you would use a 2 prong cord to run to a 3 prong receptacle?

Quote:

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Originally Posted by Shera

I love the design, it looks slick, but I'm just wondering, is there any advantage to this over a basic lamp dimmer (under $10), or is it just a nicer appearance?

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No there isn't. This is just something you can put together yourself if you have parts lying around. You don't have to go with a metal box. There are plastic ones that are cheaper. I just think the metal looks cool and they have always worked for me. :sweeet:

Quote:

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Originally Posted by Raven01

Curious why you would use a 2 prong cord to run to a 3 prong receptacle?

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Thats what they had at walmart. The neutral acts as ground but yes if you have the 3 prong wires they are better. Just what I could find. Thanks :)

Quote:

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Originally Posted by led-zep

No there isn't. This is just something you can put together yourself if you have parts lying around. You don't have to go with a metal box. There are plastic ones that are cheaper. I just think the metal looks cool and they have always worked for me. :sweeet:

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Ok, cool, it does look really nice with the metal box.

The 2 wire service cord I found at walmart is usually used for power tools that are double insulated (this box isn't). But this is what I found and it will work, is it the best probably not. But since on my house 99% of the outlets are missing the grounding wire (Not my handy work) the ground wire on this plug is useless anyway.

This is cool and all, but I really don't think the average person with little to no knowledge of proper wiring should even attempt this, and rather just buy one of these for half the price:

http://www.homedepot.com/p/Lutron-Cr...0#.UmxbdZGzfRo

Quote:

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Originally Posted by The Serpent Merchant

This is cool and all, but I really don't think the average person with little to no knowledge of proper wiring should even attempt this, and rather just buy one of these for half the price:

http://www.homedepot.com/p/Lutron-Cr...0#.UmxbdZGzfRo

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Aaron. With all do respect, if this was even remotely hard I couldn't do it. I'm not saying you need to be an electrician, but if you can change an outlet in your house you can do this.