Inline Splice for small diameter wire

Phishfry

Phishfry

I am looking for suggestions for ~AWG28 sized wire. I want inline slice. I bought some inline crimp splices that are 24-28AWG but seem too big.

Any suggestions on small diameter splicing? Prefer to avoid butt splices.

I could twist the wires together and use shrink wrap tube but I need smaller stock. My shrink wrap is too big.

Soldering in this case seems excessive.

I am splicing an Dell GPS cable connector to USB 2.0mm/pitch header cable.

Whats your trick for joining a pairing of 5 small wires?
 
Soldering and heat shrink. You can buy small heat shrink. Just twisting them together will not last with any vibration.

If you can order replacement connectors, it might be easier to just make a new longer cable.
 
I have heard of people using super glue to coat the wires but I wouldn't do it long term. I agree with ralphbsz.

Of course, I'm the type of guy who would. If you ever saw a picture of the original transistor in the lab, it looks like something I would put together.
1769870867715.png
 
drhowarddrfine said:
I have heard of people using super glue to coat the wires but I wouldn't do it long term. I agree with ralphbsz.
Click to expand...
In the early days of surface mount, shops that printed and stuffed circuit boards used super glue to keep the components in place just before wave-soldering each side. They later learned that cyanoacrylic is slightly corrosive.

Back to the OP's question - yes, strip the two wires bare, slip on a snip of heat shrink tubing, slide it out of the way, twist the wires together (inline), heat and dab on some solder, slide the heat shrink tubing over the exposed wire, and apply heat. I've used a cigarette lighter or the wide part of a pencil iron for this last step.

I prefer #1 in the diagram below.

1769883220544.png
 
Phishfry said:
I am splicing an Dell GPS cable connector to USB 2.0mm/pitch header cable.
Click to expand...
I missed this part.

You likely want something like this:

1769883834455.png

Ideally you'd buy the proper crimp tool. No solder required. If you don't have the correct crimp tool, you can fudge it using pliers and ordinary wire-strippers but the quality of the crimp would be as good. A dab of solder will solve that. So - either purchase the crimp tool or apply solder to the crimped pins.
 
I'm always amazed at the beautiful work a good pcb solder tech can do. Back in my computer hardware design days, I had a layout guy design my circuit board. It was beautiful. Had my technician solder all the parts on but it didn't work. Not that I didn't expect problems but surprised it failed so badly. Turns out, the layout guy drew the four buffer chips in upside down.

I was devastated. The board was multi-layer and expensive. Frank, my tech, said, "Let me see what I can do." Just a couple of hours later, he gave it back to me with thin wires neatly grouped around the four chips as if it was meant to be that way. Powered it up and it worked like a champ.
 
drhowarddrfine said:
I'm always amazed at the beautiful work a good pcb solder tech can do. Back in my computer hardware design days, I had a layout guy design my circuit board. It was beautiful. Had my technician solder all the parts on but it didn't work. Not that I didn't expect problems but surprised it failed so badly. Turns out, the layout guy drew the four buffer chips in upside down.

I was devastated. The board was multi-layer and expensive. Frank, my tech, said, "Let me see what I can do." Just a couple of hours later, he gave it back to me with thin wires neatly grouped around the four chips as if it was meant to be that way. Powered it up and it worked like a champ.
Click to expand...
I ran into something similar at one point. CPU, things were routed wrong (address lines), good tech lifted and created a swizzle board that flipped things.
 
ralphbsz said:
If you can order replacement connectors, it might be easier to just make a new longer cable.
Click to expand...
I have this. New connectors with wire ends for the Dell Module.. I have the kit to make 2.54mm/p connectors but not 2mm. The dupont wire end kits are pretty common.
unitrunker said:
You likely want something like this:
Click to expand...
Same. Pitch is for standard motherboard header. I need 2.00mm/p for an embedded project adding GPS to USB2.0 headers.
Jetway PicoITX w/J4105

hedwards said:
You can get solder seal wire connectors that both solder and heatshrink in one step. It's probably the easiest way of getting the job done reliably.
Click to expand...
That might be what I want. I don't need the heavy jacket of the inline splice. With five of those it gets bulky. Have to stagger them but I want short as possible.
Trying to crimp the last few ones can be a real pain in a short harness..

I need a dupont wire kit for 2mm/pitch connectors.
 
Phishfry said:
Whats your trick for joining a pairing of 5 small wires?
Click to expand...
Twisting em together and covering it with electrical tape :p

I chopped the Gameport end off a Sidewinder joystick and wired a random USB end to it, and it worked nice for FlightGear!
131276639_222364299257799_8886518924425462759_n.jpg


Before I had female breadboard wires in the Gameport end, and at the end I wrapped the wires in tape and covered it in a cable sleeve:
130869005_222364315924464_566582012484938762_n.jpg


For a HDD speaker I jammed safety pin ends and secured with tape :p I haven't learned how to solder yet, but so far get by!
 
I see your dupont bonding technique uses painters tape.
I like to use the one strip method for wire joining.
Start with one wire pair twist good wrap then fold next pair on top with a wrap and so on until finished.
Works for testing. No flames yet.
 
I did make a very ugly rig for a USB jack/UART on my Upboard with the usb2 header consisting of JST 1.0mm/p 10pin

I have one Upboard1 with Windows on eMMC and no USB jack works. So death until win removed. May need to short the eMMC to fix.
 
Espionage724 said:
Twisting em together and covering it with electrical tape :p

I chopped the Gameport end off a Sidewinder joystick and wired a random USB end to it, and it worked nice for FlightGear!
View attachment 25195

Before I had female breadboard wires in the Gameport end, and at the end I wrapped the wires in tape and covered it in a cable sleeve:
View attachment 25196

For a HDD speaker I jammed safety pin ends and secured with tape :p I haven't learned how to solder yet, but so far get by!
Click to expand...
This is an abomination unto DIN and VDE. The work of a heretic, surely

drhowarddrfine I have seen boards where some chips were superglued on belly-up and all pins nicely soldered on 5mm of wire to the board. Seems to happen from time to time.
 
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