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?
Those are the wrong pins for that housing. The pins you want look like this:
Check out Sparkfun.com for crimp pins and housings. Pololu.com also has nice crimp pins and housings.