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DIY Servo Plugs

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I've started to get a bit obsessed with wiring, and one problem's always been servo leads
I used to coil them up but they eventually slacken, so I bought the kit to shorten them from www.cpc.co.uk

Tool; Multicomp HT-225D (CPC Part CN16614)
Crimps; Multicomp 2226TG (CPC Part CN14576)
Housing; Multicomp 2226A-03 (CPC part CN14556 )
The housing's not an exact version of a servo plug, it doesn't have chamfers on the underside, but not many of my receivers have chamfered apertures now anyway.
It's also possible to get the old plug off without wrecking it, so replacement housings aren't always necessary.

First step - Remove wires from housing
Lift up the locking device with a thin blade - if it seems stuck, push the wires towards the end of the plug to disengage the lock from the crimp - they move forward about a millimetre
serwir-0.jpg

Then cut the crimps off, and shorten the wires
serwir-1.jpg

The wire needs stripping to match the crimp - about 3mm of insulation needs to come off
serwir-2.jpg


serwir-3.jpg

A crimp in all its glory
serwir-4.jpg

insert the crimp into the tool and compress it ever-so-slightly to form a round tunnel (this also traps the crimp in the tool and stops it falling out
serwir-5.jpg

insert wire, you can feel when the insulation bottoms out against the section of the crimp that retains the exposed wire
serwir-6.jpg

Squeeze handles to crimp the assembly, it should look like this afterwards
serwir-7.jpg

Then slide it back into the housing
serwir-8.jpg

The weapons
serwir-9.jpg

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Huh. I've always cut out a section of wire in the middle and soldered the ends back together and heat shrunk them to avoid playing with the connector.

Your solution is Cadillac.

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My soldering's not so great Willy - I think in a former life I was a shipyard welder :lol:

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At least the welder is a skilled craftsman...! :P I'm more like the scrapyarder with the oxy torch, breaking up oceanliners for scrap

Seen the installs where they've changed all wires to same 1 colour!? hehe Resistance is Futile (or just darned waste of energy)

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I cut the plugs and re crimp too. I also have a stash of new housings - the little retaining tabs break easy.

Soldering is another valid option, but unless you are confident with circuit boards and have invested in the right gear (de soldering tools, correct shape/size tip - plus a good iron) there is a risk of burning the board and/or causing other joins to fail.

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Ironically the first joint to fail is often the crimp :( so I usually solder the little wire into the crimp contact. Same with every other crimped join - just warm it up & flow a little solder in.

Usually takes less time than waiting for iron to warmup; most time taken by extracting the pins out of their plug bodies.

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Good crimpers make a massive difference. I find my crimps are stronger and less likely to fail than the factory ones.

I do add a little solder sometimes as well though. Especially if it is a plug that gets removed often.

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haha yeah... people around here seem to love pulling out wires by the cable not the plug :P

Just had to bust out the solder station... nice tools always much nicer to work with. Dropped a torch last night and it stopped working, so decided to reflow all its joins... and since it was already open, extracted it's puny little LED and replaced it with a white 16,000mCd unit. Seems to have double the light now :)

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