Making a great sounding mini-plug aux. iPod cable
Materials needed:
4 - equal lengths of
small gauge wire. I would recommend using 24 or 28 AWG
hook-up wire in different colors for this project (preferably
solid conductor copper)
2 - Neutrik gold plated
3.5mm mini-plugs
Parts Express Deal of the Day
Changes every business day at Midnight Eastern
? - Braided metallic
shielding. This is also available on Parts Express
2 inches- shrink tubing
Silver solder
Step by Step instructions:
Step #1 - Cut your hook-up wire in to four equal lengths. Make each wire slightly longer than you need when finished. Braiding the wires will use up some length.
Step #2 - Place an end of each wire in a vise or twist them together and hang them on a nail.
Step #3 - Braid the wires together in the Litz flat braid pattern. It takes some practice but once you get the hang of it it goes fast.
Step #4 - Twist off the wires on each end to hold the braid and strip the outer jacket of each wire on both ends approx. 1/4".
Step #5 - Place the black barrels on the wires and solder the mini-plug connectors on to the wires. Solder the two positive leads first, then solder your two ground wires to the large ground strap. I find this to be easier unless you're using a larger gauge stiff wire. If so, solder the ground first.
Step #6 - I skipped this step in the video due to time limitations but this is very important. Test your cables with a continuity tester, making sure that the two center pins on each end have continuity as well as the outside ground. We are not responsible if you short something out or damage your gear. DIY at your own risk!
Step #7 - Crimp the strain relief tabs over to pinch the wires at the base of the connector. Be careful not to pierce any of the insulation with the tabs.
Step #8 - (optional) The metallic braided shield is purely cosmetic but it adds a nice stainless steel your cables.
Step #9 - (required if you complete step
7) Cut two 1 inch pieces of shrink tube.
Place the shrink tubing over the mini-plug covering about half of the black
barrel. Using a torch or heat gun slowly warm up the shrink tube until
it has fully contracted. This will form a tight seal
and add some additional strain relief to your cables.
Step #10 - This is the best part. Listening to your new cable.
