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Step 4Soldering and Heatshrink!
While the connectors were setting up (cure time is 24 to 48 hours, but it takes at least a day to really set up), I added the plug to the computer side connector. Don't forget to put the heat shrink over the wires BEFORE you start soldering anything or you will not be able to get small enough heat shrink over the plug.
I used a small bit of sculpting clay to mold the flat end of the connector to a more streamlined shape. This was then covered with heat shrink, layered in smaller diameters until it fit the wires snugly.
The same clay technique was used again on the outlet side connector, though not pictured. The clay was added in a cone just to the left of the soldered wires in the last picture, covering the already heat shrunk twisted wires. (Last picture. this soldering step was taken after the second epoxy molding as the positive terminals had to be added after the first epoxy mold had cured)
I used several layers of heat shrink to provide additional strain relief and ensure that the energized wires were adequately insulated. In the end it creates a nice finished cord look.
I used a small bit of sculpting clay to mold the flat end of the connector to a more streamlined shape. This was then covered with heat shrink, layered in smaller diameters until it fit the wires snugly.
The same clay technique was used again on the outlet side connector, though not pictured. The clay was added in a cone just to the left of the soldered wires in the last picture, covering the already heat shrunk twisted wires. (Last picture. this soldering step was taken after the second epoxy molding as the positive terminals had to be added after the first epoxy mold had cured)
I used several layers of heat shrink to provide additional strain relief and ensure that the energized wires were adequately insulated. In the end it creates a nice finished cord look.
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