MOTM

Because of the number of Oakley and Blacet Module conversions I am 
working on at the moment I am having to put together a number of 
MOTM style PCB power connecting cables.

I have made up 13 cables so far.  AAARRGH!

Does anyone know of an easier way to put these accursed things 
together?  

I am clamping the connector bodies in a small vise, then putting 
each wire in place and jamming them in using a small bladed 
screwdriver.  I have avoided gouging myself so far but have come 
pretty close a couple of times, not to mention the blister on my 
palm.

There has got to be a better way.  

I would imagine that Paul uses some sort of crimping or insertion 
tool, but I also imagine that could be quite expensive and not 
necessarily the way to go when making up 20 or 30 cables.  

Any ideas???

--- In motm@y..., "paulhaneberg" <phaneber@o...> wrote:
>
> I am clamping the connector bodies in a small vise, then putting 
> each wire in place and jamming them in using a small bladed 
> screwdriver [...] There has got to be a better way.  

The least expensive option is the manual "T handle" tool.  This tool 
works OK for terminating small numbers of MTA IDC connectors by hand.  
Some people seem to disagree on this but I say, if you take a minute 
to figure this tool out, it works a *lot* better than a flat 
screwdriver.  You still need to clamp the connector in a vice when 
terminating the wire but, again, this tool will produces better 
results if used properly.  This tool is under $20.

T-Handle tool for MTA156 connectors (MOTM power)

AMP (manufacturer) part number 59804-1
Digi-Key part number A9981-ND
Mouser part number 571-598041


If you need the smaller MTA100 connectors for any reason (for example, 
I think these are used on "dot com" modules?) the equivalent tool is:

AMP (manufacturer) part number 59803-1
Digi-Key part number A9982-ND
Mouser part number 571-598031



The next step up is the "pistol grip" crimp tool - and it will cost 
you about 10x to join the club.  (You have to buy the "crimp die" and 
the pistol grip frame as two separate pieces, which totals about 
$150.)  The nice thing is this tool holds the connector shell for you 
and there is a little slot you feed the wire into.  Squeeze the 
trigger and the wire gets pressed into the connector and the connector 
shell advances to the next terminal position automatically.  This 
tools works good enough for "limited production run"

The pistol grip frame part numbers:

AMP (manufacturer) part number 58074-1
Digi-Key part number A2031-ND
Mouser part number 571-580741


The die set for MTA156 (MOTM power connectors)

AMP (manufacturer) part number 58247-1
Digi-Key part number A1999-ND
Mouser part number 571-582471


The die set for MTA100 (if you need this size)

AMP (manufacturer) part number 58246-1
Digi-Key part number A1998-ND
Mouser part number 571-582461



> I would imagine that Paul uses some sort of crimping or insertion 
> tool, but I also imagine that could be quite expensive and not 
> necessarily the way to go when making up 20 or 30 cables.  

As I recall (from a phone conversation) Paul has the power cables made 
to order.  The place that does this work for him terminates the 
connectors on a fancy machine.  (Some of these machines actually use 
the same "die set" as the pistol grip tool but the manual frame is 
replaced by a machine cycle.)


Paul does have power cables available on the official MOTM order form 
- if you don't want to build them yourself (or don't want to invest in 
the tools) you could always just order extra cables from Paul.


Seth

I use needlenose pliers - the kind with squared off ends. Open the 
tips slightly and place so that they press to either side of the 
blades. Works OK for a few, I wouldn't want to put a bunch together 
using this method.

Moe

I strip the wires back about 1/4", insert them lightly into the 
blades and then solder them into place. With a very pointy soldering 
tip at 800 degrees it works quite well. After they're soldered I 
squeeze some GE Silicone onto the top and snap the cover on. I've 
been making them this way for years with no problems.

Good Luck,

Richard.



 --- In motm@y..., "paulhaneberg" <phaneber@o...> wrote:

> Because of the number of Oakley and Blacet Module conversions I am 
> working on at the moment I am having to put together a number of 
> MOTM style PCB power connecting cables.
> 
> I have made up 13 cables so far.  AAARRGH!
> 
> Does anyone know of an easier way to put these accursed things 
> together?  
> 
> I am clamping the connector bodies in a small vise, then putting 
> each wire in place and jamming them in using a small bladed 
> screwdriver.  I have avoided gouging myself so far but have come 
> pretty close a couple of times, not to mention the blister on my 
> palm.
> 
> There has got to be a better way.  
> 
> I would imagine that Paul uses some sort of crimping or insertion 
> tool, but I also imagine that could be quite expensive and not 
> necessarily the way to go when making up 20 or 30 cables.  
> 
> Any ideas???