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Strain Relieving Phono Plugs

04/20/2009 3:26 PM

To build an audio headphone or patch cable using the phono (mono or stereo) plug, 1/8" or 3.5mm, or the RCA type, there comes the issue of the strain relief. Most data sheets identify the semi-circular grip at the extreme end of the plug as a strain relief.

I have not yet found a definitive answer to this. Having tried all of the crimping tools we have here with lousy to terrible results, I am turning to the group for the correct answer.

Does anyone know how to crimp this strain relief, and what tool is used to gain a professional look to the completed cable?? I know that the shell covers the affected area, but I would like the crimp to look professional should someone open the backshell.

Thanks for any help you may provide...

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#1

Re: Strain Relieving Phono Plugs

04/20/2009 3:59 PM

Professional results!!? I've seen the wires tied in knots, taped, rolled and melted and other extremes. If these are the little D shaped clips, usually pinching them on the flat side to form a slight V downward is sufficient to grasp the cable. If someone steps on the wire and rips it out, they shouldn't expect it to stay intact. Once you crimp it you can always slide a short piece of shrink tube over it and apply heat-to-shrink. This will make a finished look and provide a little more relief to the cable. this way even a messy little crimping will be hidden from prying eyes. They also figure you went the extra yard to secure the wires properly.

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#2

Re: Strain Relieving Phono Plugs

04/20/2009 4:11 PM

Guest,

I would try to contact the connector manufacturer to see what tooling they recommend. The "cleanest" looking cables are going to have molded strain relief, but you have to have the quantities to make that financially feasible.

Tom

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#3

Re: Strain Relieving Phono Plugs

04/20/2009 4:23 PM

Lacing.

Scroll down to the bottom.

Used it for years, never a call back.

Pretend you are begging a lacing and whip tie the portion under the backshell.

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