Custom EV Charging Port Solution: A Legacy Crafters GC Project

Introduction

At Legacy Crafters GC, we thrive on solving unique challenges with creative, custom solutions. Recently, a client approached us with a tricky issue involving their electric vehicle (EV) charging setup. They needed a way to charge their EV without pulling it into the garage, while also addressing safety and weatherproofing concerns. This project pushed us to think outside the box, and we’re excited to share how we crafted a tailored solution. Let’s dive into the details!

The Challenge

The client’s setup presented three key problems:

1. EV Charging Connection Location: The 240V EV charging connection was located inside the garage, requiring the client to run a cable to the outside.
2. Charging Without Garage Entry: The client wanted to charge their EV in the driveway without pulling the car into the garage, which wasn’t always practical or convenient.
3. Unsafe Cable Management: The current workaround involved running the charging cable under the garage door, causing the door to rest on the cable—a safety hazard that risked damage to the cable and potential electrical issues.

After searching for ready-made solutions, we found nothing that adequately addressed all three issues. It was clear this project required a custom approach, blending functionality, safety, and weatherproofing.

The Solution: A Custom Through-the-Wall Charging Port

To tackle this, we turned to innovative modifications and high-quality materials. Here’s how we brought this project to life:

1. Materials Selection We sourced a Newhouse Electric Weatherproof Box as the foundation for our solution. This box was ideal for its durability and weather resistance, perfect for protecting the EV charging cable outdoors. To complement it, we selected a 5” RV cable port to enhance waterproofing and ensure a secure fit for the cable.
2. Customization Process
• Modifying the Weatherproof Box: We bored a 3½-inch hole in the rear of the Newhouse Electric Weatherproof Box to accommodate the EV charging cable, ensuring a snug fit that maintained the box’s integrity.
• Adapting the RV Cable Port: We modified the 5” RV cable port to integrate seamlessly with the weatherproof box, creating an additional layer of protection against the elements.
3. Installation
• We identified a suitable location on the exterior garage wall near the existing 240V GFI connector to minimize cable run and ensure accessibility.
• Using precise measurements, we bored a hole through the garage wall to create a clean pass-through for the charging cable.
• The modified Newhouse Electric Weatherproof Box was mounted on the exterior wall, secured with four #6 screws for stability.
• To ensure a weather-tight seal, we applied high-quality caulk around the box where it met the garage siding, preventing water ingress.
4. Final Touches The charging cable was carefully routed through the modified box and port. The charging end fits perfectly inside the weatherproof box, allowing the client to store it securely when not in use. The setup is clean, professional, and built to withstand the elements.

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The Outcome

The result? A fully functional, weatherproof, and safe EV charging port that meets all the client’s needs:

• The client can now charge their EV in the driveway without pulling into the garage.
• The cable is protected from damage, eliminating the unsafe practice of running it under the garage door.
• The weatherproof box and RV port ensure the setup is durable and resistant to rain, snow, and other elements.
• The charging end is easily accessible yet securely stored when not in use, maintaining a tidy and professional appearance.

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Why This Matters

This project is a testament to Legacy Crafters GC’s commitment to custom solutions. EV ownership is on the rise, and with it comes the need for practical, safe, and innovative charging setups. By combining off-the-shelf components with tailored modifications, we created a solution that’s both functional and built to last. This project also highlights the importance of addressing safety concerns—like avoiding cable damage under garage doors—while enhancing convenience for EV owners.

Call today 973-277-0417

Have a unique home improvement challenge or EV charging need? At Legacy Crafters GC, we specialize in turning your vision into reality with craftsmanship and creativity. Contact us today to discuss your next project, and let’s craft something extraordinary together!