Custom Junction Boxes & Terminal Enclosures
A junction box gives field wiring a place to land: terminals on a rail, cables entering through the wall, and a cover that comes off with the box mounted. K-Display builds each box around your fitting sizes and terminal rail.
Junction boxes and terminal enclosures we build
Boxes from palm size to about the size of a shoebox, cut and formed from carbon steel, galvannealed steel, galvanized steel, stainless steel, or aluminum. Each has a screw-on cover, entry holes, conduit knockouts, and gland openings punched to your fitting sizes, and studs or clinch nuts inside for a terminal rail. A box leaves the dock bare, powder coated, or with the terminal rail and cover fitted.
A subpanel of drives and relays goes in one of our control panel enclosures, and an HMI at the machine goes in an operator console.
Cable entries take one wall of the box and the cover takes the top, because wiring and service do different jobs. Four screws hold the cover and it carries no fitting, so it lifts straight off and the entry wall stays undisturbed.
Junction box and terminal enclosure parts we make
- Box bodies
- Shallow and deep formed or welded bodies with mounting tabs and a mounting pattern for the terminal rail.
- Entries and knockouts
- Punched holes and retained conduit knockouts sized to the fitting.
- Gland plates
- Plates punched for multi-cable entry through one wall of the box.
- Covers
- Screw-on covers with gasket lands and the screw pattern.
Fittings, terminals, and the cover joint
- Entry spacing
- Conduit hubs and cable glands need wrench room around each fitting. Entries set too close leave no space to tighten either one, and the fitting stays loose in the wall.
- Terminal reach
- Terminal screws are tightened with the box mounted, so rail position and block height decide whether a screwdriver reaches them. A rail set too deep leaves the lower screws out of reach once the wires are landed.
- Cover joint
- A thin cover on a long span bows between its screws. A cover that bows opens the joint at the gasket land.
- Mounting surface
- A wall, a machine frame, and a pole put the box in different orientations. A mounting tab placed in front of an entry blocks the fitting, and the box has to come off the surface to change it.
Entries first, rail last
An opening punched too close to a bend distorts when the body is formed, so each entry is placed on the flat pattern with the bends in view.
Punch and form
We punch the entries and knockouts in the flat blank, laser cut the outline, and form the body, cover, and mounting tabs.
Weld the corners
We weld the corners of carbon steel, stainless steel, and aluminum bodies, then install the studs and clinch nuts for the rail.
Coat and fit
We powder coat the box, then fit the cover and terminal rail, and pack the box or the loose parts.
Leave room around the entry fittings
Two entry holes can fit on a drawing while the fittings leave too little room for a wrench. Check the full fitting bodies and the tool’s approach with the neighboring gland installed, as shown here. The wrench needs room to engage the flats and move.
Repeat that check inside the box, where locknuts compete for space with terminals and the box walls. Use the selected fitting drawings and installation instructions to establish the spacing; wall thickness and seals also affect how the threaded entry seats.
The wrench needs room beyond the gland's outline to engage and turn. Spacing the entry holes around the installed fittings and tool approach makes the connection accessible after neighboring cables are fitted.
What to send for a junction box quote
- Box model
- STEP or DXF and a PDF with overall dimensions, mounting tabs, and cover style.
- Entries
- Hole diameters and centers, fitting part numbers, and knockout positions.
- Contents
- Terminal blocks or rail, component height, and conductor approach.
- NEMA type
- The type your design names and the surface the box mounts to.
- Material and finish
- Material and gauge, powder color, and any faces left bare.
- Quantity
- Boxes per order and the delivery date.