Drilled bad hole in side of coach for solar plug - Now What?

[Nookaroos]

We're in the process of installing portable solar panels on our coach -- our first major improvement undertaking since we purchased new. The pre-installed Zamp plug will only handle 100 watts of power so we're installing our own plug.

From under the carriage we removed the expansion foam and checked for wires where we wanted the plug and it looked clear. My husband started drilling a 1 1/8" hole and after getting about half way he stopped and found that we are drilling into what looks like a piece of support metal. We can't see that much to know what's really in there. Pictures attached.

My husband thinks it's okay to drill all the way through as he pictures the support as a box section and we're only taking a small piece out of it. I see the support as an L-shaped corner piece and that if we drill all the way through we will completely sever the support.

We've put the tools away and we sure could use some advice on how to proceed and/or how to repair the hole we've drilled should we need to move it.

Thank you in advance for your assistance
The Nookaroos

2017 Forest River Forester 2431S
25'9"Class C with no overhead bunk

[cabranch47]

I personally would not continue drilling. Plug the hole with the plug from your hole saw and seal it for waterproofing. Then cover it with some type of vent cover, outlet cover, small marine inspection port, anything that might look like it was factory installed. Just my thoughts.

[NJKris]

Yikes! I like CAbranch's suggestion. Why didn't you just pull the Zamp receptacle and replace it? BTW, it might not be the plug itself than can only handle 100W, but the wiring behind it to the batteries, in which case you would only need to upgrade to heavier wiring.

[5picker]

I would not continue drilling in that spot.

You've compromised the stud a bit but with the bonded walls it should't be an issue but I wouldn't continue and cut it off.

Move the hole over and plug the original with either the original cut-out or the one from the new hole. Many folks who "oops" something like this fill the hole and then put a decal over it.

BTW... on a colder/damp morning you can see all the structural studs outlined on your R/V side walls.

[llr]

How deep is the actual plug you are using?

If it will fit in the current cut depth I would use a dermal and cut that tab off as the tab is not adding anything at this point. then route the wires to the left of the stud.

[Nookaroos]

Hopefully this will be enough to convince my husband that we need to stop and move the plug.

To answer your questions. We didn't reuse the Zamp plug or hole (wish we had now) because it looked too complicated to try and redo what was done and because the hole is on the "wrong" side of our door from where our controller is and we're trying to minimize wire lengths -- we would have had to figure out a way to put the wires around our stairwell.

The plug is too long to fit in the existing cut hole -- in fact it is long enough to probably go all the way through so that's not an option.

Regarding the tip from 5picker to see the studs, we live in San Diego so we're not likely to have a cold/damp morning for quite some time. I'll keep that in mind for the future though.

Anyone else have any ideas for how to find the studs?

Has anyone had any luck getting a plan of their coach from Forest River so we have an idea of where studs, etc are? I suspect the plans aren't good at saying where "movable" things like wiring is but at least we'd have a good idea.

Nookaroos

[donbledsoe]

The right kind of stud finder will find metal studs.

[NJKris]

I have a pretty good Franklin ProSensor, it could not find studs on back wall. Ended up driving a screw through exterior wall trying to hang a towel rack.

[nvs4602]

I would use the old plug as suggested then fill the gaps around it with spray foam trim any excess off. Use a little body filler. The put a sticker over it. You could have the paint matched and get a spray can of paint made to pant over it too. A good auto parts store or body shop can order the spray paint for you. Just take the next piece you cut out in and they can match it perfectly. Kind of like the hrdware stores do when you take a color sample in and the can match it.

[formerFR]

I think since you've already drilled thru 3/4 of the structure, leaving it like it is is not going to do anything different than if you just go the rest of the way - install your new plug, and have a pretty install - otherwise, how are you going to now 'pretty' this?

Keep going, and be done with it.

[MtBiker]

I would just drill a bit to the left and make up a plate to mount on there that covers the right side of the hole and gives you room to mount your plug. A nice rectangle of aluminum with your hole for the outlet and 4 corner holes to secure the plate. Easy and you don't have to go searching for another location.

[tinkerreknit]

Originally Posted by cabranch47

I personally would not continue drilling. Plug the hole with the plug from your hole saw and seal it for waterproofing. Then cover it with some type of vent cover, outlet cover, small marine inspection port, anything that might look like it was factory installed. Just my thoughts.

My vote! You'll forget about the boo-boo immediately.

[TheWolfPaq82]

Originally Posted by MtBiker

I would just drill a bit to the left and make up a plate to mount on there that covers the right side of the hole and gives you room to mount your plug. A nice rectangle of aluminum with your hole for the outlet and 4 corner holes to secure the plate. Easy and you don't have to go searching for another location.

I think you made an excellent suggestion. A nice cover plate and move a little to the left.

[Stank Bait]

Make the cut out much larger and add some metal bent in an L. Angle from hardware store. Drill through stud and put some through bolts with nuts to make a patch in the stud, Cover with a door or plate to hide the destruction. This reinforces the stud and the larger door hides everything. 3/4 of the stud gone seems like a lot even if it is metal and cutting through the bent part took the stiffness out of it.

[Zoom]

Originally Posted by MtBiker

I would just drill a bit to the left and make up a plate to mount on there that covers the right side of the hole and gives you room to mount your plug. A nice rectangle of aluminum with your hole for the outlet and 4 corner holes to secure the plate. Easy and you don't have to go searching for another location.

Sounds like the best solution. You already know what is in the wall there!

[Go UK]

If you live in a area with morning dew. The dew will accurately outline the studs.

[NJKris]

I like the cover it with a sticker idea. I Googled 'wrong hole' to try to find a funny sticker pic. uhhhhh... don't do that. Unless you have the same sense of humor I do. Which is highly unusual among the older RV crowd, lol.

[moose074]

Originally Posted by Stank Bait

Make the cut out much larger and add some metal bent in an L. Angle from hardware store. Drill through stud and put some through bolts with nuts to make a patch in the stud, Cover with a door or plate to hide the destruction. This reinforces the stud and the larger door hides everything. 3/4 of the stud gone seems like a lot even if it is metal and cutting through the bent part took the stiffness out of it.

I agree finish the cut then find a way to support the stud and proceed no more cutting no hoping on making it go away

[Maggot]

Originally Posted by formerFR

I think since you've already drilled thru 3/4 of the structure, leaving it like it is is not going to do anything different than if you just go the rest of the way - install your new plug, and have a pretty install - otherwise, how are you going to now 'pretty' this?

Keep going, and be done with it.

Agreed. Committed to that spot and pretty much already did structure damage. Doubt it will have structure failure. Don't dwell on it it will be ok.

[BillyBass]

fill the hole with wood filler then put a decal on thats what I had to do when i hung my tv in the bedroom