Hidden EBH Plug

TheForce · 04-02-2008, 08:14 PM

I just had an idea on how I could fix my EBH so the power cable wont fail again. I doubt this idea will work because of the bumper foam but I will give it a shot anyway. So here is my idea.

I want to use one of those 15A marine plugs that are water tight. I actually all ready bought one. I hate the idea of having a black circle on the front of my bumper so I thought maybe I could put it behind the license plate. What I want to do is to put hinges on the license plate so I could just flip it up when I want to use the EBH. The EBH would go in the center of the license plate area. There is plenty of room on the outside for this but I'm worried about the inside. There is foam behind the bumper cover that may not give me enough room to install the plug. What I'm hoping to do is to maybe cut just enough foam out so the plug will fit into place. To keep the license plate from flapping around I will use some magnets since the license plate is steel. Here is a pic of what I had in mind.

The seal for the plug is missing in the pic.

This is just one of my Prius projects that I want to do when the temperature warms up.

Bear68 · 04-02-2008, 08:19 PM

You shouldn't have too much worry about cutting an opening in the foam. We remove foam from the rear bumper covers on many vehicles to install Park Pilots. (Radar assist for parking, beeps when you get too close to the car behind you)

Kremtok · 04-06-2008, 03:06 PM

I'd be very interested to hear how / if this works out for you. Please keep us posted.

TheForce · 04-08-2008, 09:34 PM

Well I have part one finished. I managed to get my license plate on a hinge with magnets holding it shut.

Some parts needed...
Brass hinges
Some special bolts I had laying around. Had to grind two bolts down to attach the license plate to the hinge.
Magnets from old hard drive
Glue

I'll try to explain above each picture.

Here you can see the brass hinges. The bolt attached to the frame is some kind of flat box top bolt. I had it lying around so I don't know what you would buy at lowes. I had to drill an extra hole in the center of the top hinge for the license plate. I also had to grind down the bolt for the license plate so it would close correctly.

Here is the back of the frame. I glued on some high powered hard drive magnents in the lower corners where the square holes are. I had these laying around also. The gap between the magnet and the plate caused by the frame make the strength of the magnet perfect for keeping the plate secure but easy to flip up.

Here it is installed. It looks stock.

Here it is flipped up.

Here is a quick video of the function of it.

Hidden Electric Block Heater EBH 2006 Prius

All thats left now is to get that plug installed. I just hope that plug I have will fit. If not I'll have to find something else to use.

ericbecky · 04-09-2008, 06:53 AM

ericbecky · 04-09-2008, 06:55 AM

This is an excellent project! It looks great. I hope to see it in person some time.

patsparks · 04-09-2008, 09:42 AM

I like it.
I hope removing some foam doesn't compromise the crash safety of the vehicle.

Could a person use 1/4 inch gutter bolts

but shorter than this one with dome nuts to reduce the profile of what has to fit inside the hinge?

TheForce · 04-09-2008, 11:20 AM

I think that should work. The bolts I used had the same thread size as the stock bolts. If your planning on doing the same thing you might want to make sure you get the same thread size so you can use the built in nuts. The bolt I used had a pretty flat head. It allowed the hinge to lay parallel to its self. I guess I could still grind this down a little if needed. I had to drill a center hole above where that bolt would be so the plate bolt would not interfere and cause the plate to stick out. I had to do some on the fly engineering to get everything to work right. I'll try to get more detailed pictures when I start to install the plug.

Brodie · 04-09-2008, 12:21 PM

Great idea and looks like it's coming along nicely! I wish I was at all handy.....but I'm not.

One thing to keep an eye on....those brass hinges in contact with the aluminum license plate will eventually cause corrosion of one or the other....I can't remember which metal will corrode the other but they will, esp in the winter with road salt. Not a catastrophic thing but it would stink to lose your license plate.

TheForce · 04-09-2008, 12:37 PM

My plate is not aluminum. I think its stainless steel. Thats why the magnets pull on the plate. Magnets wont pull aluminum.

04-02-2008, 08:14 PM	#1
TheForce I Plug-In My Prius Join Date: May 2005 Location: Wheelersburg, Ohio Posts: 2,702 My Car: 2006 Prius Model: Package: #7 Thanks: 1 Thanked 143 Times in 106 Posts Friends: 22	Hidden EBH Plug I just had an idea on how I could fix my EBH so the power cable wont fail again. I doubt this idea will work because of the bumper foam but I will give it a shot anyway. So here is my idea. I want to use one of those 15A marine plugs that are water tight. I actually all ready bought one. I hate the idea of having a black circle on the front of my bumper so I thought maybe I could put it behind the license plate. What I want to do is to put hinges on the license plate so I could just flip it up when I want to use the EBH. The EBH would go in the center of the license plate area. There is plenty of room on the outside for this but I'm worried about the inside. There is foam behind the bumper cover that may not give me enough room to install the plug. What I'm hoping to do is to maybe cut just enough foam out so the plug will fit into place. To keep the license plate from flapping around I will use some magnets since the license plate is steel. Here is a pic of what I had in mind. The seal for the plug is missing in the pic. This is just one of my Prius projects that I want to do when the temperature warms up. __________________ 2006 Prius Barcelona Red Package #7. Picked up 2006/01/02 Converted to Plug-In on 2008/08/12 with Hymotion L5 *Hybridfest 2007 & 2008 Peoples Choice Award * *Hybridfest 2009 Peoples Choice Best of Show Award * For a list of my mods visit http://www.jaygroh.com

04-02-2008, 08:19 PM	#2
Bear68 Senior Member Join Date: Mar 2007 Location: West Palm Beach, FLA Posts: 306 My Car: Model: Package: Thanks: 4 Thanked 8 Times in 7 Posts Friends: 7	Re: Hidden EBH Plug You shouldn't have too much worry about cutting an opening in the foam. We remove foam from the rear bumper covers on many vehicles to install Park Pilots. (Radar assist for parking, beeps when you get too close to the car behind you)

04-06-2008, 03:06 PM	#3
Kremtok Smug Alert! Join Date: Apr 2008 Location: Anchorage, Alaska Posts: 53 My Car: 2008 Prius Model: Package: #3 Touring Thanks: 0 Thanked 0 Times in 0 Posts Friends: 1	Re: Hidden EBH Plug I'd be very interested to hear how / if this works out for you. Please keep us posted.

04-09-2008, 06:53 AM	#5
ericbecky Senior Member Join Date: Mar 2004 Location: Madison, Wisconsin Posts: 436 My Car: Other Hybrid Model: Package: N/A Thanks: 9 Thanked 28 Times in 24 Posts Friends: 45	Re: Hidden EBH Plug <duplicate post> Last edited by ericbecky; 04-09-2008 at 02:31 PM.

04-09-2008, 06:55 AM	#6
ericbecky Senior Member Join Date: Mar 2004 Location: Madison, Wisconsin Posts: 436 My Car: Other Hybrid Model: Package: N/A Thanks: 9 Thanked 28 Times in 24 Posts Friends: 45	Re: Hidden EBH Plug This is an excellent project! It looks great. I hope to see it in person some time.

04-09-2008, 09:42 AM	#7
patsparks An Aussie perspective Join Date: Jul 2007 Location: Adelaide South Australia Posts: 9,027 My Car: 2004 Prius Model: N/A Package: Base Thanks: 108 Thanked 174 Times in 133 Posts Friends: 33	Re: Hidden EBH Plug I like it. I hope removing some foam doesn't compromise the crash safety of the vehicle. Could a person use 1/4 inch gutter bolts but shorter than this one with dome nuts to reduce the profile of what has to fit inside the hinge?

04-09-2008, 11:20 AM	#8
TheForce I Plug-In My Prius Join Date: May 2005 Location: Wheelersburg, Ohio Posts: 2,702 My Car: 2006 Prius Model: Package: #7 Thanks: 1 Thanked 143 Times in 106 Posts Friends: 22	Re: Hidden EBH Plug I think that should work. The bolts I used had the same thread size as the stock bolts. If your planning on doing the same thing you might want to make sure you get the same thread size so you can use the built in nuts. The bolt I used had a pretty flat head. It allowed the hinge to lay parallel to its self. I guess I could still grind this down a little if needed. I had to drill a center hole above where that bolt would be so the plate bolt would not interfere and cause the plate to stick out. I had to do some on the fly engineering to get everything to work right. I'll try to get more detailed pictures when I start to install the plug.

04-09-2008, 12:21 PM	#9
Brodie Senior Member Join Date: Mar 2008 Location: Rhode Island Posts: 158 My Car: 2008 Prius Model: Package: #2 Thanks: 0 Thanked 1 Time in 1 Post Friends: 0	Re: Hidden EBH Plug Great idea and looks like it's coming along nicely! I wish I was at all handy.....but I'm not. One thing to keep an eye on....those brass hinges in contact with the aluminum license plate will eventually cause corrosion of one or the other....I can't remember which metal will corrode the other but they will, esp in the winter with road salt. Not a catastrophic thing but it would stink to lose your license plate.

04-09-2008, 12:37 PM	#10
TheForce I Plug-In My Prius Join Date: May 2005 Location: Wheelersburg, Ohio Posts: 2,702 My Car: 2006 Prius Model: Package: #7 Thanks: 1 Thanked 143 Times in 106 Posts Friends: 22	Re: Hidden EBH Plug My plate is not aluminum. I think its stainless steel. Thats why the magnets pull on the plate. Magnets wont pull aluminum.

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