Outlet Box Options in C-Channel Workbench Leg

[A&P mechanic]

Hi guys

What is the best way to add an outlet housing inside of this C-channel? Does anyone have any better alternative solutions?

I searched for one gang “narrow” outlet housings but it looks like those do not exist. I am considering cutting the rectangle hole bigger with a multi tool and sliding a metal outlet box into the rectangle hole. I realize this will weaken the C-channel and am open to better suggestions.

I will use NM (nonmetallic)/Romex in the future instead of an extension cord for the electrical cable going to the outlet. I would like a metal 1-gang housing instead of plastic and I will ground the metal 1-gang housing. I would prefer to use this existing hole. I will post pictures of the completed work but it may be several weeks before I action item this.

Attached is a picture of the outlet box with the wings I am considering using.

If anyone has a better alternative, I would like to hear it. Thank you!

 

[Bucko]

I would surface mount a box and use a clamp on NM connector from the back of the box thru the hole you already have. Use a metal outlet plate for strength. Wouldn't be as pretty but would be alot safer.

 

[yeldogt]

I had bench years ago with those outlets in the side rails -- it had a very thin bent metal box. It was a global industries. Why not google and see what they use now. You just want to stop something from getting in there by accident.

 

[PugetDude]

Just put it in a single gang handy box , run the screws through the front; use the c-channel leg as the cover.

 

[A&P mechanic]

Surface mounting would work with a metal outlet cover but I would prefer if it was flush. I feel the box is more protected inside the C channel. I found a picture on Google where somebody mounted a surface box on a similar workbench leg.

I looked at the Global Industries brand but I prefer the outlets I already have since I can charge my phone with the USB port. Plus, I already cut a rectangle hole as shown instead of the two separate holes that were in the leg originally.

I think using single gang box in the below picture seems like the best idea so far, where I run two longer screws through the front of the leg to attach the box from the back. I am still open for any upgrades to this specific idea or any other alternatives. Good ideas everyone.

 

[jrsavoie]

I've made my own boxes on occasion when nothing was available to meet the dimensions

 

[PCustoms]

Old work metal box?

Handy box tacked to the frame?

 

[jmarkwolf]

I had bench years ago with those outlets in the side rails -- it had a very thin bent metal box. It was a global industries. Why not google and see what they use now. You just want to stop something from getting in there by accident.

I found a cheap set of stamped bench legs at a garage sale years ago, that had the outline of duplex outlets stamped directly in the sheet metal of the legs. You would simply remove the punch-outs and install the duplexes. Don't know how you would "enclose" them for safety.

 

[CraigStu]

I am wondering why the need for a box. The leg already covers the front and two sides. Couldn't you just make a cover for the back?

 

[Half-fast eddie]

Do you really need another outlet in the front? You already have 2 pair. Why not add an outlet on the back leg. Some things are going to stay plugged in for a long time, like that fan, don’t need quick access to the outlet. Save the front outlets for temporary use.

 

[fuggle]

Can't you just use the two holes you already have and screw the box to the C channel with those? The box would be flush to the inside.

 

[A&P mechanic]

I am going to use a handy box with longer screws to attach the box from the back so it is flush. I am installing the wires in a box opposed to just covering the back of the C-channel since I do not want a kid to put his or her fingers back there etc.

I already have outlets on all four legs from many years ago. I have a drill press, bench grinder plugged into the back. I may add an outlet on the wall in the future to free up the outlets on the bench.

I am looking into using SJOOW to make the cable with a plug for the outlet, I like how SJOOW has more protection versus the standard NM Romex that I plan to use under the bench. I am not the biggest fan of attaching braided SJOOW to an outlet but it will work. I prefer to use solid wire because it wraps around the screw terminal easier versus braided but am leaning towards SJOOW since the big box stores sell it by the foot.

Would you use SJOOW cable with a plug going from the bench to the wall or something similiar? If you recommend an alternate cable for the bench to the wall, then what is it and why? Thank you.

 

[A&P mechanic]

Thank you for the electrical guidance earlier. The handy boxes were a perfect fit.