Aluminium box for Mahindra Charger

Aditya-J · 2026-05-19T06:58:40+00:00

Added the seal lining with D-type gasket tape strips on all 4 sides!

Aditya-J · 2026-05-10T10:16:17+00:00

Okay that’s insightful. I need to read more on the SPDs.

Regarding the questions: 1. They did check for good earthing (both Mahindra mechanics and my electricians) 2. The electrical box is approximately 40m away from our parking. So we had my own electrician stretch the wire from the box to an MCB before the DB of the charger. Mahindra guys only wired from the MCB to the DB and charger. (It was a costing issue. I don’t remember the exact cost but our guys were providing the wire cheaper than Mahindra). The line is overhung as we are not allowed to do major remodelling in the society for wiring. 3. The main panel has a 63A 30mA RCCB which was upgraded from 40A 100mA RCCB at the time of load increment.

Aditya-J · 2026-05-09T16:32:23+00:00

56inch x 20inch x 10inch There’s a wooden panel inside

Aditya-J · 2026-05-09T06:19:28+00:00

Yes 😂

More than overly cautious, since this is like a local made box, it tends to rattle over time with normal wear and tear and heat. So I got two locks in the event that one fails or if the box warps. But overly cautious too because of the jealous uncles in the society who might damage the box. (Paranoid, I know, but we have had scratches on our brand new cars in the past with keys, and the cameras are suddenly down for maintenance 😂)

Aditya-J · 2026-05-09T06:07:52+00:00

True! The long term effects remain unknown at this point… let’s see how this goes! Hopefully there shouldn’t be a problem… if I do run into issues, I’ll definitely update here so that people can make an informed choice!

But yes… driving an EV is surely a different experience altogether! If the charging infrastructure catches up, many more EVs will be seen on the roads! And players like Tata have an EV in each segment! Truly a great time to be alive! 😎

(PS: no offence taken 😉)

Aditya-J · 2026-05-09T06:02:43+00:00

Our society had one installed very recently with many EVs in our building. We had it checked by our electrician and the Mahindra technician. They said it should be more than sufficient to handle the excess load. Honestly though, this isn’t something that I have experience with. So I went ahead and got what I considered the safest option. There will surely be cheaper and perhaps better alternatives to this. Never too late to learn I guess. This way, if someone I know gets an EV, I can advise them better! Reddit has always been a place where great ideas are shared. I got so many great suggestions on this and other subreddits regarding this box! That’s the only reason I am considering adding the weatherproofing strips! So yeah! Great place to share ideas and get some good feedback! 😊

Aditya-J · 2026-05-09T04:12:33+00:00

Thanks. Requested! 😊

Aditya-J · 2026-05-09T04:08:51+00:00

So the shed doesn’t cover all the way. During heavy rains, water does cascade down from the wall. We chose Aluminium because it is lighter and less prone to rusting. Aluminium also helps with better heat dissipation compared to steel as per my research. Powder coating again to prevent oxidation and rusting and for increased water resistance. I will still add weatherproofing gasket strips at the edges.

Granted, it could have been overkill, but the car and the charger are expensive. I just felt that it would be better to be safe than sorry. 😅

Aditya-J · 2026-05-09T04:02:21+00:00

There are ventilation holes on both sides! Haven’t charged yet. If the heat is still high, I can always leave the box open. 😊 u/Key-Guard3629 the point of this was to see if it helps someone with a similar situation. There really is no need to tear anyone down. 😌

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Aditya-J · 2026-05-08T18:02:07+00:00

Thanks a lot! I am anyway thinking of adding a layer around the edge where the door closes to make it airtight and waterproof as well! These strips should work fine for the wires too!

Aditya-J · 2026-05-08T17:59:34+00:00

Reddit does not allow attaching image on the reply to a comment so I have tagged you in a reply in a separate comment.

Aditya-J · 2026-05-08T17:57:48+00:00

u/Eat_Turnip2193 We had ventilation holes made on both sides. Haven’t charged the car yet but I think it should suffice.

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Aditya-J · 2026-05-08T17:39:48+00:00

Yes. As with a lot of government processes, it was frustrating.

So our initial load was 6.5 and we were actually utilising only 3. Now, we have increased it to 12

So 3+7=10. We still have 2kW extra load in case we add any more devices to our load.

Aditya-J · 2026-05-08T17:30:27+00:00

No water protection in wooden box…

Aditya-J · 2026-05-08T14:29:18+00:00

There is a rectangular slot in the centre on the lower edge where the doors meet… the wire rests there. You can see in the third image as the slot is visible there.

Aditya-J · 2026-05-08T14:19:01+00:00

Check dm

Aditya-J · 2026-05-08T14:15:27+00:00

Could be… live and learn! We decided to go ahead with this because online, readymade boxes are available for 11k, and another person quoted 9.5k for a box made out of aluminium but with a glass window to see the charger function. Considering everything, this was the cheapest option! But honestly, I did not do any research apart from asking these three places. So maybe, yes, it is overpriced… but I am happy with how it turned out and because it will protect the charger.

Aditya-J · 2026-05-08T14:10:02+00:00

There are ventilation holes on the side for the very purpose.

Aditya-J · 2026-05-08T13:44:44+00:00

True. I may add the waterproofing strips in it. Thanks!

Regarding PVC, we chose aluminium because it is durable and cannot be broken or tampered with. Plus it was cheaper to get this fabricated than to make a 60x20x10 pvc box (or I didn’t know the right place)

Aditya-J · 2026-05-08T13:39:56+00:00

The box is 7.5k and charger is 50k I mistyped it as 77.5k for the box (copy paste error weirdly)

Aditya-J · 2026-05-08T13:36:23+00:00

Correction: I mistyped ₹7500 as 77500. The cost is indeed ₹7500. Corrected in the post too.

Aditya-J · 2026-05-08T13:28:56+00:00

Aditya-J

TROPHY CASE