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When I box a old chassis, I use .125" (1/8") plate, UNLESS it's going to be a chassis that's going to get a motor that makes big-torque or if it's going to be beat on, then I use 3/16".
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Choosing the right size of screws for these boxes is crucial to ensure a secure and stable installation. The most common electrical box screw size is 6-32, but for heavier applications, 8-32 or 10-32 screws are used. The thread pitch for all these screw sizes is 32.
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