[aprssig] Making molded connectors and potting

Daron Wilson daron at wilson.org
Mon May 23 15:16:01 EDT 2005

Thanks, good site and good information.  I've tried the hot glue, in fact
when I make things in D shells that are permanent I usually shoot them full
of hot glue prior to closing them, keeping the cord from any movement and
making it secure.  I've tried potting assemblies with Bondo, and epoxy, but
never got quite what I wanted.


I found liquid latex in all sorts of colors, non-toxic too, but it's really
designed for other stuff :-)


Still looking for the easy way to make molded plugs, and the dual plug
radios are definitely a challenge.  I've done that with hot glue but it's
not as solid of a connection as I wanted.






From: aprssig-bounces at lists.tapr.org [mailto:aprssig-bounces at lists.tapr.org]
On Behalf Of Keith Kotch
Sent: Monday, May 23, 2005 11:48 AM
To: 'TAPR APRS Mailing List'
Subject: [aprssig] Making molded connectors and potting


In my line of work, one of our customers is a major avionics manufacturer
for whom I do some environmental monitoring in their production facilities.
One of the rooms that I check is where they pot electronics and crt
displays.  I always like to see these processes and it spurs me to think how
nice I could make projects look and last if I adopted such concepts as
potting and creating molded connectors.


In asking around it was suggested that I look in Arts and Crafts stores for
molding supplies.  I did run across this company at a local store:


Looking at some disc samples of the different molding compounds makes this
stuff look promising.  I don't know about dielectric properties of the
material but since it's rubber-like or plastic-like in some forms I don't
think that would be a problem.


Keith, KF4BXT



From: scott at opentrac.org
Subject: RE: [aprssig] FW: D-sub connector components


Digi-Key and Mouser should both have all of those parts.  I can suggest some
part numbers for the 9-pin connectors and backshells.  I carry those on my
own site as well:  http://n1vg.net/opentracker/purchase.php


The backshells come with all the hardware.  For the side connecting to the
GPS cable, you might want connectors with integrated clinch nuts.  Digi-Key
carries a couple thousand d-sub connectors and they've got the best
parametric search around.


Let me know if you find any good homebrew techniques for overmolding.  I've
done some stuff with hot melt glue when necessary, but that's about it.  I
need some custom molding myself - I've got to make cables for Motorola
handhelds, and the spacing between the 2.5 and 3.5 mm plugs is too small for
separate connectors.  Mouser sells plugs designed for overmolding, but aside
from investing some serious money in tooling and injection molding, I don't
know how you'd use them.




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