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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
  • Subscribers 530 subscribers
  • Views 3709 views
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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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Top Replies

  • 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…
Parents
  • 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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  • shabaz
    shabaz over 1 year ago in reply to dougw

    Here they are dirt cheap from CPC (a Farnell/Newark company). Maybe this brand might be available in your country too.

    image

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  • shabaz
    shabaz over 1 year ago in reply to dougw

    Here they are dirt cheap from CPC (a Farnell/Newark company). Maybe this brand might be available in your country too.

    image

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  • dougw
    dougw over 1 year ago in reply to shabaz

    Newark does sell them, although they all seem to have flanges.

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  • shabaz
    shabaz over 1 year ago in reply to dougw

    Oh.. the metal flange is useful for gathering the strands. You definitely want them without flange?

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  • beacon_dave
    beacon_dave over 1 year ago in reply to shabaz

    Perhaps need to be careful when going cheap that they are still DIN 46228-1 etc. so as to get a consistent crimping quality.

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  • shabaz
    shabaz over 1 year ago in reply to beacon_dave

    I've used that brand for a few years, they are tinned copper (like the DIN standard requires). The dimensioning tolerances might be different though. But even with the DIN standard, there's actually very few guidelines on wire thickness matching to ferrule size, and a lot of the ferrule crimpers have just the single hole for accepting all sizes of ferrules. But agree one shouldn't cheap out for a critical application. And definitely avoid complete no-name products which might not even be the correct material.

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  • dougw
    dougw over 1 year ago in reply to shabaz

    Both types would be useful.

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  • beacon_dave
    beacon_dave over 1 year ago in reply to shabaz

    A while back I had some ferrules that tended to stick in the die of the crimp tool after crimping. I think the standard helps more with that aspect nowadays.

    With the insulated types it can sometimes be difficult to get a good fit on both the conductor and then on the insulation.

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  • beacon_dave
    beacon_dave over 1 year ago in reply to dougw

    You'll be wanting 'aglets' next for your shoelaces Mans shoeMans shoe  Slight smile

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