3D printed lock for Ford NACS adapter

[nuMach]

deterring opportunistic theft is the low hanging fruit, and safeguards the larger percentage of thefts.
a determined crook will come with tools, and a universal key (cordless grinder with zip blade)

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[JustBob]

I’m a Lightning owner but I wanted to stop by and say I found this thread via google and printed out your wedge "lock". Your design is awesome and fits perfectly in the Lightning's charge port as well (looks like the actual charging receptacle is exactly the same as the Mach-E which isn't surprising). I look forward to using it on an upcoming trip. Although it's unlikely for my adapter to be stolen, I'm confident this wedge will be effective in keeping honest people honest. Thanks!

Video of the printed wedge in action:

Cool. Glad you like it. I was working on one that locks behind the charger, but couldn't get the right combination of flexibility and durability.

 

[Aubury]

It's pretty disappointing we feel the need to make things like this cause Ford doesn't prevent charge session stoppage when the key isn't nearby or the doors are locked. Tesla obviously thought of this since you can't even disconnect the supercharger plug from the adapter while the adapter is plugged into the charge port.

Please Ford, just release an OTA update that monitors lock status and key proximity and disables the charge session stop button if those requirements aren't met. It can't be that hard to implement.

 

[Mablanc]

Here's my first attempt at 3D printing a lock for the adapter to prevent someone from just disconnecting the adapter and taking it while charging. It has 2 parts (plus a padlock). The inner sleeve that covers the release button is tapered to match the size/shape of the adapter. It has to be pushed on from the back side. I believe it's tight enough and strong enough so that it can't be pulled off the front of the adapter. Then the second piece slides up from the bottom to keep the sleeve from being pushed back. Lock together with a padlock.

I'm open to suggestions. This design does not prevent the locking lever from moving, but just prevents access to the release button. I don't believe you can pull the lever up when installed without some sort of hooked tool. Also, I left the release for the NACS plug exposed. That could be covered up as well, but thought it best to have a way to quickly unplug. I did consider some sort of hidden button lock (like a puzzle box), but thought that could be figured out. I plan to print this in black to conceal it somewhat when in use.

Just got my NACS adapter yesterday.
That looks like a great security solution. Would you share the STL file?

 

[JustBob]

Just got my NACS adapter yesterday.
That looks like a great security solution. Would you share the STL file?

It's on thingiverse.

https://www.thingiverse.com/thing:6695435

 

[Mablanc]

It's on thingiverse.

https://www.thingiverse.com/thing:6695435

Found it - thank you!

 

[Mr. Toejam]

Still works with the recall replacement adapter. Thanks again.

 

[JustBob]

Still works with the recall replacement adapter. Thanks again.

That's good to know. I haven't received my recall replacement yet.

 

[New2EV]

I remixed @JustBob 's adapter wedge lock. I was having troubles with the legs on the key breaking. The remade wedge uses a key that you insert and turn 90 degrees to pull out. A stronger key design IMO. I also made a version that can be used with the Lectron version of the adapter.

https://www.thingiverse.com/thing:6971042

 

[geftsnowball]

Nice!

Did a thing too, just haven't had time to upload anywhere. Created some variations (couple ChargePoint chargers I use have slightly different clearances on the handle clip) after coming back to cable on the ground after getting unplugged at an L2. Haven't had any breaking issues and only a couple times on really rainy days there was added difficulty pulling out with the key.

 

[bdeweese]

Thanks for sharing this! I have the Lectron Vortex (non-Ford branded) adapter. I was hoping it is the same as the Ford version - but apparently not. Unless I’m going about it wrong, I couldn’t make the “new” version work with my unit. Anyone know of a 3d print version of these specifically for the Lectron Vortex?

Thanks!

 

[New2EV]

Thanks for sharing this! I have the Lectron Vortex (non-Ford branded) adapter. I was hoping it is the same as the Ford version - but apparently not. Unless I’m going about it wrong, I couldn’t make the “new” version work with my unit. Anyone know of a 3d print version of these specifically for the Lectron Vortex?

Thanks!

Hmmm... I thought the adapters were the same. What is stopping it from working? Creating new versions is pretty easy if you can describe what I need to change.

 

[21st Century Pony]

I remixed @JustBob 's adapter wedge lock. I was having troubles with the legs on the key breaking. The remade wedge uses a key that you insert and turn 90 degrees to pull out. A stronger key design IMO. I also made a version that can be used with the Lectron version of the adapter.

https://www.thingiverse.com/thing:6971042

Thank You for this.

FYI - I found the key for Your excellent remixed adapter lock a bit short, and possibly the most fragile item in this version.

My solution and suggestion: rather than 3D printing the key, find an appropriately sized cheap steel nail in the hardware store - the nail's shank should just fit the hole in the remixed 3D adapter. Then, just Dremel off two opposing edges of the nailhead so that it's roughly rectangular and Dremel-grind the nailhead shape so that it fits into the adapter's rectangular key opening. Then, bend the key into a 90+ pulling shape and voila... a cheap-as-heck, easily replaceable, easily locatable and unbreakable adapter lock key

BTW - this modified steel "key" will work equally well for the original and for the Lectron NACS adapter 3-D locks.

 

[JustBob]

Thank You for this.

FYI - I found the key for Your excellent remixed adapter lock a bit short, and possibly the most fragile item in this version.

My solution and suggestion: rather than 3D printing the key, find an appropriately sized cheap steel nail in the hardware store - the nail's shank should just fit the hole in the remixed 3D adapter. Then, just Dremel off two opposing edges of the nailhead so that it's roughly rectangular and Dremel-grind the nailhead shape so that it fits into the adapter's rectangular key opening. Then, bend the key into a 90+ pulling shape and voila... a cheap-as-heck, easily replaceable, easily locatable and unbreakable adapter lock key

BTW - this modified steel "key" will work equally well for the original and for the Lectron NACS adapter 3-D locks.

On thingiverse, chevel2 made a remix with a more robust printed key. I think this is better than the original that I designed.

 

[Mach-Lee]

I would like to remind folks that adding a lock is no longer necessary with the current software—the car will keep the adapter locked when the vehicle is locked. This change was included with the 10.2.0 OTA and some dealer updates. If the powertrain software was updated in the past six months, you probably already have the feature.

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