DIY power cord project = PITA

Nick B · « **on:** 18 Jun 2006, 07:07 am »

I bought a DIY power cord kit a few months ago and it's been gathering dust. This weekend, I tried to do the assembly and what a pain it is. This is a red Belden cord. I believe it's called the star quad. There is a ground wire enclosed that wraps the opposite direction of the way the Belden is wound. I presume it's one ground wire only, but a diagram also shows 2 ground wires that are wrapped. Confusing. Cutting the red cover and not cutting the metal braid is quite tricky. The AC males are the Hubbell 5266 C. The IEC's are the Wattgate 320i and the Schurter 320. I don't care for any of the plugs. I asked for a solder free kit and I'm now ready to solder!! There is hardly proper room for combining 2 wires and then threading into the connectors and then tightening with a screwdriver. I have no gripe with the vendor who sold me the kit. He's a very nice guy and it's my fault for letting this sit for so long. I would like some suggestions on which AC plugs and IEC's to buy that have lots of room for combining the wires, can also be soldered and are of good quality for a reasonable amount of money. The kits were not cheap, so I'd like to try and complete them.

Carlman · « **Reply #1 on:** 18 Jun 2006, 01:16 pm »

I've built similar cords and one thing I can tell you is that when you score the red jacket, bend/flex the whole cord and let it break away rather than trying to strip it.
I don't know which connectors have better/worse holes. I'd go to HD or Lowe's and look around... or even better an electrical supply store.

-C

Kevin Haskins · « **Reply #2 on:** 18 Jun 2006, 02:12 pm »

That red Belden cable is a PITA to work with. There is no easy way to terminate it. The Belden 19364 is MUCH easier to work with.

fajimr · « **Reply #3 on:** 20 Jun 2006, 08:48 pm »

hey nick

I just built up a pobox kit from ernie that had a 9ga red wire... is this the same thing you are working with? yeah it was definitely a PITA and needed to be forced a bit but I never had to solder.

follow carlman's advice about scoring the jacket... I was a bit doubtful about everything as the wire seemed to be too big for the male plug especially but it did seem to come together in the end... no shocks yet- so I guess everything is o.k.

good luck

Nick B · « **Reply #4 on:** 21 Jun 2006, 01:01 am »

I'm getting slightly better working with this wire. Scoring and bending is much easier. Thanks for the tip. The problem still is with the wire braid. Very delicate stuff. I'll keep tinkering with it. Better figure it out soon as my cord is shrinking

Last night on some website (forgot which one), I saw an ad for Oyaide wire at about $70 a foot. Anyone used or seen this before?

Nick B · « **Reply #5 on:** 21 Jun 2006, 01:03 am »

I meant $70 a meter.

Jocko Homo · « **Reply #6 on:** 3 Jul 2006, 04:27 pm »

Have you looked at the Marinco IECs???? They do not need soldering, and are easy to work with. Parts Express carries them.

Jocko

Nick B · « **Reply #7 on:** 3 Jul 2006, 05:17 pm »

I finished one cord and soldered the wire braid to the ground wire. Much easier that way. It's a good kit. I think the instructions need to be a bit clearer and diagrams would have been helpful. I did offer that suggestion to Ernie.

Carlman · « **Reply #8 on:** 3 Jul 2006, 06:03 pm »

Oh yeah, the braid... I use what looks like a bent pick on a soldering tool... you could use an ice-pick...
I put the tip into the braid and pull it through, starting at the end, working back, loosening more and more until I reach the point at which it was stripped. It looks like a big, crazy mess of wire but it's all still connected. I then twist all of it together to form a lead. I actually enjoy that part.

-C

Nick B · « **Reply #9 on:** 3 Jul 2006, 08:15 pm »

Carlman....you enjoy that? Me thinks you have too much time on your hand

Seriously, the problem I had with the braid is twisting it really shortens it a bit and I have to gauge that and cut the ground wires to compensate. That part was a bit tricky, so the soldering was easier. BTW, I finally used a toothpick and that worked fine. Am curious about trying the cords, but I don't have 2 same cords.........which I will need for the used D200's I just picked up on Agon

EProvenzano · « **Reply #10 on:** 3 Jul 2006, 08:22 pm »

Quote from: Jocko Homo on 3 Jul 2006, 04:27 pm

Have you looked at the Marinco IECs???? They do not need soldering, and are easy to work with. Parts Express carries them.

Jocko

I second this suggestion. I've used numerous belden cables with braided shield, and these IEC's are a piece of cake to terminate.

Nick B · « **Reply #11 on:** 3 Jul 2006, 09:30 pm »

I'll check out the Marinco's as well. Thanks for the tip