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Member's Forum How do you make reliable, low-cost cables quickly?
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Forum Thread Details
  • Replies 52 replies
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  • dougw
  • bootlace connectors
  • custom cables
  • MTA
  • Yodamonk
Related

How do you make reliable, low-cost cables quickly?

dougw
dougw over 1 year ago

I do lots of electronics design and building and inevitably need to make lots of cables. Since making cables is not my favorite activity, I try to use methods that are quick while still providing reliable connections. And of course I always need to keep the costs down.

This short post shows a couple of the main ways I accomplish these objectives.

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Yodamonk, the cable guru.

Custom Cable Methods

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Discussion

I haven't posted much content lately so I thought I would post something about making cables. This activity is not usually exciting enough to be a great blogging topic, but I also wanted to play around a bit with some AI media generation. (No AI text though) The tough Yodamonk dude came out amazing.

I am always looking for efficient ways to make useful cables, so if you have any interesting tips, please jot them down below...

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  • rsc
    rsc over 1 year ago in reply to wolfgangfriedrich +4
    When I worked at Chrysler, I learned a nice way to document cables using this technique: 1) Have a picture of the end of the connector and label the connector with part number and manufacturer. 2)…
  • shabaz
    shabaz over 1 year ago in reply to dougw +4
    Here they are dirt cheap from CPC (a Farnell/Newark company). Maybe this brand might be available in your country too.
  • phoenixcomm
    phoenixcomm over 1 year ago +3
    dougw Oh, my favorite hatted thing to do in the shop! Before we can build a custom cable you have to take a long look at "TOOLING" Well if you are working with mill connectors, which I do, they come in…
  • wolfgangfriedrich
    wolfgangfriedrich over 1 year ago

    I don't have any tips. Just more questions: How do you document cables efficiently and easy to understand?

    Obvious answers would be: my favourite CAD program, Excel, Visio/Inkscape, Paint, special cable doc software, ... 

    I used to work at a company, where the 1st correct cable was put on the copy machine and scanned for documentation. 

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  • rsc
    rsc over 1 year ago in reply to wolfgangfriedrich

    When I worked at Chrysler, I learned a nice way to document cables using this technique:

    1) Have a picture of the end of the connector and label the connector with part number and manufacturer.

    2) Label what end of the connector your picture is looking at, pin side or solder side

    3) Label picture pins or sockets end, pin part number or socket part number

    4)  For each connector add a matrix table of pins to the picture listing the following

    -  Connector name, pin name, pin number, wire AWG/part number, wire color, wire length, Other end connector name, Other end pin number

    5) There may be other items on the cable to list including splices, tape areas, loom or other covering, inline fuses or fuse wire, etc.

    It takes time to document, but it's nice to have later on when diagnosing problems.

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  • dougw
    dougw over 1 year ago in reply to wolfgangfriedrich

    I store any cable docs in the project design directory and I have a subdirectory for datasheets. Pinouts are usually on the schematic or in a spreadsheet that lists part numbers, pin numbers, function and connectivity. I don't generally need photos since I generally use my standard techniques to build cables and nobody else is ever involved.

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  • electronicbiker
    electronicbiker over 1 year ago

    It depends on the cable and to what use it will be put. At the small end, vintage record players where the cartridge connects to the electronics using extremely thin extremely flexible cables, often screened. The cores, of which there are usually two or four, are even more extremely thin. Colour coding varies from manufacturer to manufacturer. Soldering is tricky because the heat travels up from the stripped end to the insulation very quickly, and the insulation melts very easily. Taking too long to solder the screen will often result in all the cores and the screen melting together. The wiring between heads and electronics in vintage tape recorders poses similar problems.

    At the other extreme there are RF screened cables 0.75" in diameter with a semi-hollow PTFE spacer between core and screen. I use them for aerial connections as part of my Amateur Radio interest, luckily I have not needed many! Waterproofing can be a problem. The core is often solid copper and the PTFE spacer is very difficult to cut using normal hand tools. If it cuts easily then it may not be PTFE. The screen is usually braided very tightly. I sometimes think a gas blow-torch would be the right tool for the soldering but I have not tried that yet. Over-bending the cables is a) not approved of because a bend is an inductor, and b) because the cable is very stiff and kinking is not allowed. Connectors are usually huge versions of BNC or huge versions of  PL259 / SO239 pairs.

    Making cables for other things, often one-offs, depends on so many variables. I like IDC for ribbon cables and use a bench-mounted vice as a crimping tool. From years ago I have mainly used DIN or Phono (aka RCA) connectors for audio leads, as well as 0.25", 3.5mm, and 2.5mm jacks, all the usual stuff. In times of sheer desperation I have used the short lengths of wire from such things as off-cuts from resistors and capacitors as pins for connecting short lengths of flexible wire to experimenter's boards, and so on.

    Going down another road there are screw terminals that can be soldered to PCB's or screwed to enclosures, spade and bullet  connectors as used in vehicle electrics, 13A mains plug and socket(s) extension cables, there's no end to it.  

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  • dougw
    dougw over 1 year ago in reply to electronicbiker

    I used to use IDC ribbon cables a lot. I'm not sure why they have declined in popularity.

    I also used IDC ribbon on D sub connectors.

    Similarly card edge connectors seem to be declining as well.

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  • DAB
    DAB over 1 year ago

    One of my first jobs as an electronics technician was to make dozens of cable for a power distribution system.

    All had to be hand soldered, which took days.

    The modern methods are much easier to use, but none of my cales failed.

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  • genebren
    genebren over 1 year ago

    I really like to use the crimp ferrules on wires that are getting inserted into screw terminals.  And old AMP IDC connectors are really nice, even if I don't have your fancy gun, only the T-handle tool (which is not so easy to use).

    image

    Thanks for sharing your thoughts on cables.

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  • dougw
    dougw over 1 year ago in reply to genebren

    Once you try crimp ferrules (bootlace connectors) it is tough to go back. I am still looking for a good source (read cheap) that are simple metal tubes - no plastic sleeve.

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  • anniel747
    anniel747 over 1 year ago in reply to dougw

    Size? Quantity?

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  • beacon_dave
    beacon_dave over 1 year ago in reply to dougw

    Farnell here sell the Knipex 97 99 910 assorted box quite cheaply

    https://www.knipex.com/en-uk/products/cable-connectors/assortment-boxes-with-non-insulated-wire-ferrules/assortment-boxes-non-insulated-wire-ferrules/9799910?v=89312  

    https://uk.farnell.com/knipex/97-99-910/ferrule-terminal-kit-w-box-1000pc/dp/2859404

    You get more than the similar Multicomp Pro box for a similar price. (1900 vs 400)

    https://uk.farnell.com/multicomp/xrbox5-en-ea481/ferrule-kit-uninsulated-5-types/dp/1734784

    Not sure if Newark do the same.

    I posted a picture of the Multicomp Pro ones in use here a week or so ago:

    /products/roadtest/rv/roadtest_reviews/58/knipex_self_adjustin?CommentId=2cb69922-5f0d-4538-a986-2d430b0fc9cd

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