A problem with these type of connectors is that they tend to loosen quickly. Like for instance the dupont pins that you can use with the male 2.54mm headers are not that great for often connecting and disconnecting, at least that is my experience.The standard cheap Chinese DuPont connectors do indeed loosen dramatically after just a few insertions.
The standard cheap Chinese DuPont connectors do indeed loosen dramatically after just a few insertions.The original pin header connector, the Amphenol Mini-PV, is rated for insertion cycles. (According to Amphenol, &#;PV&#; stands for &#;perpetual virgin&#; precisely because of the high insertion cycles.) The downside is that they cost about 100 times as much as the Chinese DuPonts. For example, I paid $14 for a roll of Chinese DuPont contacts. hand-crimpable Mini-PV contacts cost $145 from Digi-Key. (The reeled Mini-PV are a pain to use by hand because they are joined end-to-end and thus need to be cut off, very precisely, on both ends. You can&#;t just flex them off the carrier like most contacts. And even so, pcs of reeled Mini-PV would still cost $75.)With that said, I&#;ve completely switched to genuine Mini-PV for test leads, where a few hundred insertions are absolutely to be expected, so even if it cost me zero time (and wire) to replace the contact every three insertions, it&#;d still be cheaper to use the real thing. And the real Mini-PV comes in three insertion force levels, and the highest force ones (intended for connectors with just a few pins) hold really well, so much better than the Chinese DuPonts could ever hope to on their first insertion!But for internal wiring that&#;s just to assemble and then leave alone, the Chinese DuPont contacts are fine.Somewhere in between are things like JST XH and Molex KK, whose curled-back spring contacts don&#;t loosen anywhere near as much as the single-bend Chinese DuPont contacts. (But they&#;re not as robust as Mini-PV, which uses a separate beryllium copper leaf spring inside the brass body.) Some, like KK, are available in both brass, which deforms easily, and phosphor bronze, which is more resilient. Genuine JST XH contacts are phosphor bronze (brass by special order), but clones may be brass, you often don&#;t know. Chinese DuPont contacts are brass.There are other 2.54mm pin headers connectors that are better than the Chinese DuPonts, but not as good as Mini-PV, like Molex C-Grid and SL, and Amphenol Dubox, which is rated for 200 cycles.
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Grumpy_Mike:
It's the top part of the connector, it is what pushes down on the top part of the ribbon cable and clips in.
All the IDC connectors I've seen have semicircular indents on that portion of the connector which wrap around the wires. That looks like it might be some kind of tape you have to peel the backing off of. Or perhaps it's just some cardboard which is there to prevent the connector from seating in place during transit? I think I got some connectors once with something like that.
And they're $4 each
Is that expensive to you?
When I need to make or get 50 of these cables manufactured and I'm working on a shoestring budget? Yes.
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Anyway, thanks for the help guys. I determined that it was cheaper and easier to just get the cables manufactured.
This was what I was planning to do originally on one end of the cable:
But for what it would have cost me for the 300' of ribbon cable and IDC connectors (the second rainbow cable was another $100 on top of that), I was able to get 375' of cable with crimp connectors on each end plus housings, so I can have the cable terminate with the proper connections instead of doing a half-assed job. I was only considering the IDC connectors because the other option would have been crimping connectors by hand myself, and aside from having no interest in doing that, I was also pressed for time.
This is what the cable is for by the way. It's a 7.5' long cable which extends all the switch, strobe, and vibration motor cables from the gun to the backpack:
http://www.mightymicrocontroller.com/kits/proton-pack/
In the videos, the kit is installed in the gun, but many people wanted to be able to install it in the backpack so as to have more room in the gun for tip extension mechanisms and speakers and the like.
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