Wiring Connection integrity

Projects General Guidance
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You gotta have one of those fancy router jigs to cut those dovetails. No way
those are handcut! Lol

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Did you make your own templates?

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Not yet, but im working up to it. I just bought a 5w (output) cutting/engraving laser. I also have a desktop CNC.

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Laser cutting 3/16" pine -- from a slabbed 2x4

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Christmas ornaments for friends with pets

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You can get PH pre made wires on ebay.

These would be soldered with the connectors between those components that might need separation.

Examples:

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Soldering in intermediate connections is a lot of work. If everthing is duponts you can use M-F pairs as extensions. The cable shrouds also come in a slip in version that can be used without cutting the cables. This allows all your interconnects to be duponts and you can add disconnects and extensions with ease and no need for soldering or stocking anything but duponts. There is also a cable holder that will prevent dupont to dupont connections from disconnecting, but in practice the added retention of the shrouds means most all dupont-DuPont interconnects work just fine without.

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For me, it is a case by case scenario:

  • connections to arduino board - crimped dupont in 8p housing. More pins inserted more rigid the connection
  • power distribution - 2 wago lever clamp connectors; wires inside terminated with crimped uninsulated ferules.
  • screw terminals - crimped insulated ferules
  • relay outputs for high current (10A) - 5 cm 1.5 mm2 wires soldered directly on the relay pins on one end and plugged into wago connector at the other end
  • low power cable connectors outside automation (arduino) box - JST SM 2.54 crimped
  • high power cable connectors - crimped uninsulated ferules, then wago
    For crimping ferules I use a hexagonal shape crimper.
    Crimping dupont and jst not easy. There will be a lot of crimps that does not hold well if you pull the wire. In such cases I try to double the bare wire and crimp it folded. Many times the crimped connector will not go into the housing easily and most of the times I have use the ferule crimper to correct the shape of the insulation crimp.
    Generally speaking, solid wires will not hold well in a crimping connection.
    I tried soldering before. It's fine too, but it seems to me that, after I cover the connection with heat shrink, It's permanent, I cannot modify it. While the the crimped connector can be extracted from their housing.
    All the above it might seem to be much, but I work on projects like a dyi heat pump. If one sensor fails, I have no more heat. Not to mention the cost of damaging the pump itself.
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thanks for that tip Larry! :+1:

29

Good information to know....thanks...