attn ChiXJeff! or other electronic geeks

[Beezil]

hey.

I'm ina pickle.

I am doing a job for Spector of the UK who is the POP purchaser for Nokia.

I need some serious electronics help!

I have to interface some crazy nokia cord into some mini amp board using customer supplied Molex-Waldom KK interconnection system crimp terminals, for the .100" center connectors.

(Newark PN 44f8234)

the thing is, the wire diameter is .005" (a pair) in a clear insulator that measures .009" the pair of wires are insulated by thin jacket measuring .045 across.

the wire is pretty damn skinny, probably skinnier than 30ga. which is the minimum size of wire the connector calls for.

its too late to re-engineer this stuff. Its customer-supplied material, and its here. My ship-date quickly approaches.

not only is stripping the wire a bitch, but crimping thm in the connectors is near impossible.

The brainiest people in our operation struggled to complete just one set, the fact that i have to do hundreds and hundreds of them with un-skilled labor is a major problem....

I am looking to out-source this sub assy to a company or individulas who do this sort of thing for a living, and are willing to stand behind their work.

Jeff, or any other chicagoland geeks (affectionate term) do you have any ideas for me?

this one really bites.

 

[ChiXJeff]

Yeesh.........

Try calling Flextronics, Solectron, or another contract electronics shop. Or, Gawd forbid, Manufacturers' Services, Ltd (my former employer....)

You may also want to check your ThomCat for cable assemblies.

As a side note, there are companies like http://www.cabco-usa.com/customcables.html. I've bought a single cable from them (PC SVGA video to SGI monitor) and they were good to deal with.

More stuff (http://www.google.com/search?sourceid=navclient&q=+custom++cable++assembly):

http://www.microdotconnectors.com/custom.stm
http://www.cables-and-networks.com/manufacturing.html
http://www.meritec.com/

 

[Rev Den]

Try.....

http://www.lanatech.ca/index.html
http://www.pasternack.com/
http://www.bb-elec.com/
http://connectivity-products.com/index.html

I have delt with the first one alot, I do not know if they will handle what you got...but they do very good work. I have purchased from Pasternack and BB also, they offer good service and seem to stand behind thier product.

Not much help here....worth a shot.

If the wire is too small you COULD bend it over to double its thickness. Make sure you have the correct crimpers and strippers for your wire and connectors, chances are a "universal" crimper is NOT gonna work. What about soldering it?

Rev

 

[ChEwBaCcA]

Beezil , you most likely need a special crimp tool. We get into a few AMP plugs and terminals at work . There are different crimp tools for almost every connector they make. These are NOT your run of the mill crimp tool , they are hand helds/press, but they cost up to $1200 per.

Also sounds like you need a special stripper for that ga. wire....we got a few different types at work...again its in the tools.

30 gauge ouch thats small ....also note there is probally specs on how to use those terminals on that style of wire very important if its to stay in the terminal.

Give me a ring if those places want crazy money for the job., i may be able to work something out for you guys.

I think i got access to a hand press that will do 30 ga.

Regards
Chewy