Help on crimping wires for analog inputs...

I have just purchased the OpenCockpits Analogue Axes Card and I'm using it to interface an old joy-stick rigged up as a cyclic-collective. Everything works well, but I have a fundamental problem with crimping the wires for the female 3-way connectors that fit onto the (3-way male) analogue inputs.

I have been using wire cutting pliers - Very Gently(!) - to crimp the internal connectors of the 3-way 'plug' to the very fine (to me, at least!) wires, but wonder if there is a crimping tool available - preferably from a U.K. source. Any other advice - i.e. soldering etc - would be gratefully received.

By the way, I'm really pleased with the OpenCockpits Analogue Axes Card. It worked straight out of the box and required almost no software adjustment other than the usual setting up procedure (properties) in FSX.:!:

Many thanks!

Cheers - Dai. 8-)

Hi,

A couple of times I have used these:

http://www.maplin.co.uk/colour-singl...t-cables-98848

with the 'pointy bit'/male end screwed into a standard connector block, the cable screwed into the other side of the block and then the female end pushed onto the connector pins on the interface card. May not be cheap but works... I would rather solder but as you say can sometimes be a bit fiddly...

Cheers
Mike

I use servo extentions cables, these are mega cheap from ebay. They just slot over the pins!

Hi Alex,

You got a link for those to see what kind of thing you meant?

Cheers
Mike

Here you go buddy:

http://cgi.ebay.co.uk/20-x-50cm-Serv...item27bbff6661

Cheers,

Alex

Guys

If you are reasonably handy with a soldering iron then the easiest and cheapest way to make "made to measure" cables using these components.

Crimp connectors:-

http://www.rapidonline.com/Cables-Co...terminal/63799


Selection of varying pin number connectors

http://www.rapidonline.com/Cables-Co...n-system/63798

Method

Trim back 2/3mm of insulation and crimp the first "ears" of the connector around the insulation. Crimp the second set of "ears" around the bare wire - I use pliers.

Then I put the crimped assembly vertically into a small worktop stand and very lightly apply some solder only to the area between the two crimps. Too much solder and it will spread onto the "spring end" of the crimp terminal (bad news) or melt the insulation! Then you just push the solder crimp into the plastic connector - get it the right way round so that the tiny little tag can locate into the rectangular hole in the plastic connector. You can also remove the wires later by using a point to press the little tag in and then pull on the wire

It all sounds far worse than it is - a little practice soon gives you the hang of it. Tedious?, possibly, - strong, yes - gives you purpose made lengths - correctable yes

Over 1500 made on my sim so far!!

David

Well, many thanks!

@ Mike - these single ended pin interconnectors look just right for the digital inputs on the OpenCockpits' card,

@ Alex - the cables look really professional, I'll probably go for these on the next build,

@ David - great mini-tutorial!

It's really good to get help when you're just starting out - thanks again!

Cheers - Dai. 8-)

Hi,

I used to buy these from maplins:

http://www.maplin.co.uk/pcb-terminal-1491

These are the same as fordgt's version but i just soldered the wire to the terminal and put 10mm of heatshrink round the terminal and wire connection. About 100 odd made so far, never let me down!

Alex

Thanks, Alex - these are very much the same as the terminals I received from OpenCockpits, when I ordered the Analogue Axes card. Your point about the heatshrink round the terminal is a good tip - thanks!

Cheers - Dai. 8-)