A thin seal for an electric switch, comprising:
- (a) a unitary seal having a hollow cavity, said seal having an upper portion and a lower portion;
- (b) a nut, said nut having an exterior surface and a threaded interior surface, said exterior surface including a polygonal external surface, said nut having a top planar surface and a bottom planar surface, said nut having an opening to said threaded interior surface of said nut;
- (c) said lower portion encapsulating said exterior surface of said nut;
- (d) said upper portion of said seal having upstanding side walls and an enclosed top portion, said upper portion being smaller in diameter than said opening to the interior threaded surface of said nut;
- (e) said lower portion being larger in diameter to said opening to said interior threaded surface of said nut, said lower portion having an opening in its base portion at least as large as said opening to said interior threaded surface of said nut;
- (f) said lower portion having an extension of said seal confluent with said bottom planar surface of said nut facing away from said upper portion of said seal, said extension being positioned a spaced distance below and in a parallel plane with said bottom planar surface of said nut, said extension forming a redundant liquid and dust tight seal when said seal is in place on said electric switch;
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- (g) said seal being formed by placing said nut on a vertically positioned pin having an upper first section configured in a desired shape of said upper portion of said seal, said upper first section of said pin having a diameter smaller than said opening to said interior threaded surface of said nut, said pin having a lower second section having a diameter larger than said opening to said interior threaded surface of said nut, said pin extending upwards from a planar surfaced mold, said nut being held a spaced distance above said planar surface of said mold by a shoulder formed at a junction of said first and second sections of said pin by said different diameters of said first and second sections of said pin, then placing a thin sheet of polyurethane plastic over a top portion of said nut, vacuum forming said sheet of plastic over said pin, thereby creating said thin electric switch seal by encapsulating the outer surface of said pin and said nut in a film of said sheet of plastic, then stripping said film off of said pin, and cutting said film at an area on said planar surface of said mold slightly larger than an area encompassed by said polygonal external surface of said nut at said shoulder of said pin so as to free said seal from remaining portions of said film, so that when said seal is secured to a flange on said electric switch with said switch extending upwards into said hollow cavity, said switch is free to move within said cavity without interference from said seal.