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Topic: Trying to assemble custom cables and housings? (Read 2 times) previous topic - next topic


Dec 31, 2012, 11:12 pm Last Edit: Dec 31, 2012, 11:35 pm by h4t Reason: 1
I've created a board that has 2-pin, 3-pin and 4-pin 0.1" male headers that are all meant to connect to off-board components like other boards, LEDs and potentiometers. I ordered some housings from Digikey that fit my headers just fine, but I'm having a really hard time getting the crimp contacts to fit!

Here is an example of the 4-pin housing that I got: http://www.digikey.com/product-detail/en/0022013047/WM2002-ND/26435
And here are the crimp contacts, which are listed as an Associated Product for the housing above: http://www.digikey.com/product-detail/en/1375819-1/A100453CT-ND/2233146

I am using solid core wire from an ethernet cord (24AWG I believe).

I can get the contact crimped to the wire just fine, but when I try to insert it into the housing there is significant resistance. Even when I take pliers and push hard, all that happens is the crimp contact snaps in half!

Is there another tool I need to make this work? Maybe the crimp contacts are not good for my housings (even though they are an Associated Product on Digikey)? Does anyone have some info about how to assemble my own cables like this?

Or is there maybe a better interconnect solution that I don't know about to get off-board components wired up?
Grad student, creative technologist, OSHW engineer

Jack Christensen

I may be missing it in the associated product list. The first thing that caught my eye is that the housing and pins you linked are from different manufacturers, which doesn't mean they don't work together, but...

FWIW, I find connectors a huge pain. Very difficult to find just what I want, mating parts, etc., especially when places like Digi-Key or Mouser list about a million part numbers. Real needle in the haystack.
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Looks like your housing is Molex series "KK® 2759" and the pins are TE Connectivity series "CST-100 II". Probably best to stick with one manufacturer and series.
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I find the crimp terminals, crimp terminated wires, and crimp housings from pololu.com all work well together.

For ribbon cable/IDC, I've been getting parts from phoenixent.com.  Lot easier to find stuff vs buried at digikey/mouser.
Getting ready to make up 28 cables to connect a breakout board to 28 dual-7-segment display boards.

digikey does have a good selection of JST connectors, I've designed the 1.5mm, 2.5mm, and 3.5mm pitch connectors, both thru hole & surface mount, into several boards (2,3,4,5,6,8 pin variants). Someone else ordered the mating JST female header with wires, we crimped pololu pins onto the flying leads and put them into crimp housings to mate with AVR ISP programmers, USB/Serial boards, and other boards.

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Great responses, thanks. It looks like the 2 and 4 pin housings I ordered were from the KK series, while the 3-pin housings were from the CST series. When I went to order the crimp contacts, I grabbed contacts that were associated with the CST series, not the KK series.

I've decided to go with bare male headers so that the housings don't need to be polarized or have anything fancy on them (locking ramps, friction lock, etc.). I found housings such as the following in the KK 2695 series: http://www.digikey.com/product-detail/en/22-01-2031/WM1576-ND/1090454

The following crimp pins are in the Associated Products list: http://www.digikey.com/product-detail/en/0008500113/WM1114CT-ND/467980

But the crimp pins are in series KK 2759 series. I have a hunch that the numbers are less indicative than the letters (KK), but does anyone know for sure what that naming scheme is about?
Grad student, creative technologist, OSHW engineer

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