Strengthen molex AKA style crimps/wires

by Goldie

I've started getting a lot of orders for chaos dm3 and alias boards.

I'm wanting to make some more PC cables so people with an old enough PC could still use it.

We went and used the aka pico blade molex across the "board". Yes, I intended the pun!

Also, I'm doing a lot of drone stuff and this connector is becoming pretty common.


My problem is the wires do not like to be moved much one they're crimped. You can put then in a static position and they'll stay forever. Put them in a high vibration or where they're being pulled in and out of the socket and they break like crazy.

I've been trying to find a way to strengthen this for years. Maybe I'm googling the wrong term, but others have to have this complaint.

Anyhow, I've tried super glue, hot glue, really soft aircraft rtv,epoxy, spit and bodily fluids and nothing has worked.

My brain tells me that the strain relief I'm trying isn't going to work if it's not connected to the housing because it will still let the wires flex at that point and add extra weight to the joint. There just isn't any extra meat on the connector housing to glue to.

I haven't found another style of housing that they offer. I haven't looked to see if anyone has been clever and 3d printed something.

I have guys wanting cables, but I'm not going to sell them unless I can keep them from breaking.

Any ideas

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Posted on Jul 17, 2017, 1:47 PM

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  1. What part exactly is breaking?. James, Jul 17, 2017
  2. Need more data. HHaase, Jul 17, 2017
    1. Sorry!. Goldie, Jul 17, 2017
      1. What type of wire is being used?. J.Cook, Jul 17, 2017
        1. It varies in size a bit, but always stranded.. Goldie, Jul 17, 2017
    2. Agreed. need more information.. J.Cook, Jul 17, 2017
  3. Effing Molex connectors. Dave H, Jul 17, 2017
    1. Re: Effing Molex connectors. Antknot, Jul 17, 2017
    2. Need not-molex. Kunkmiester, Jul 18, 2017
      1. Maybe the Packard Weatherpack is better. Bruce Bergman, Jul 24, 2017
  4. how are you stripping the wires?. James, Jul 17, 2017
    1. Answers. Goldie, Jul 17, 2017
      1. wires. smorizio, Jul 18, 2017
  5. Seen this?. Snowtroll, Jul 18, 2017
    1. That's a good point. Dave H, Jul 18, 2017
      1. Where'd my picture go?. Dave H, Jul 19, 2017
        1. Unless someone fixed it for you. Bruce, Jul 19, 2017
          1. Huh. The internet is messing with me.. Dave H, Jul 19, 2017
  6. The answer to most things..... RobAGD, Jul 28, 2017

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