Two Questions:

A. How to machine holes through metal cabinets?
I want to install a IEC female power receptacle in a
metal cabinet. What is the easiest way to accurately
cut-out the opening?

B. I would like to build a 6' - 95-100% shielded power
cable to carry 100-125 VAC, 25 watts. I would also like to
use the Synergistic Research A/C Master Coupler as
a model. http://www.synergisticresearch.com/atlas7.htm
This design uses two separate runs of "woven stranded
shield/ground solid core." The core wires are stranded "long
grain hyper pure copper." Couldn't something like two runs
(hot/cold) of very high quality coax carry a 25 watt load... what
is the minimum gauge needed?

Am I right in assuming that the outer wire shielding from
each run would be tied into the common ground on the
male/female IEC outlet receptacles... using this model?

C. Are there any manufactures of inexpensive finished
power cords ( $100 per 6'/95% or better shielded) that
would allow me to cut just off the female end and hard
wire it through the existing round power cord opening in
the cabinet?

Powell wrote:
Two Questions:

A. How to machine holes through metal cabinets?
I want to install a IEC female power receptacle in a
metal cabinet. What is the easiest way to accurately
cut-out the opening?

(1) Drill pilot hole + mounting holes
(2) Use nibbler to rough out hole
(3) File hole to finished size


B. I would like to build a 6' - 95-100% shielded power
cable to carry 100-125 VAC, 25 watts. I would also like to
use the Synergistic Research A/C Master Coupler as
a model. http://www.synergisticresearch.com/atlas7.htm
This design uses two separate runs of "woven stranded
shield/ground solid core." The core wires are stranded "long
grain hyper pure copper." Couldn't something like two runs
(hot/cold) of very high quality coax carry a 25 watt load... what
is the minimum gauge needed?

First and foremost, you want a power cord that is safe. Minimum of 300 volt
insulation is required.

Within that context:

(1) Twinaxial cable
(2) Two-conductor twisted pair
(3) Multi-conductor twisted pair with with pairs in parallel

Am I right in assuming that the outer wire shielding from
each run would be tied into the common ground on the
male/female IEC outlet receptacles... using this model?

Yes.

C. Are there any manufactures of inexpensive finished
power cords ( $100 per 6'/95% or better shielded) that
would allow me to cut just off the female end and hard
wire it through the existing round power cord opening in
the cabinet?

Check the Belden & Alpha catalog - see a Belden and/or Alpha distributor

"Powell" wrote in message
...


C. Are there any manufactures of inexpensive finished
power cords ( $100 per 6'/95% or better shielded) that
would allow me to cut just off the female end and hard
wire it through the existing round power cord opening in
the cabinet?

Yes, and you will get better shielding, because the two conductors generate
opposing magnetic fields. This means the residual field handled by the
ground braid will be smaller and easier to shield against.