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[Old Guide, see updated version] Make and sleeve your own extension cables!

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Martin S
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Re:[Guide] Make and sleeve your own extension cables! 2010/02/16 13:33:55 (permalink)
Thanks Zach, that's a very reasonable price. I look forward to the pics!

thor88: You're welcome. I just tried out that "di-sleeving" you were talking about, I'll post some pics soon.
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ZachA
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Re:[Guide] Make and sleeve your own extension cables! 2010/02/16 14:03:16 (permalink)
Heres the pictures... If you need any one color or another just let me know which one you want. 
 
$10.50 per 100' spool for 18awg
$13.30 per 100' spool for 16awg 
 
If you want anything large like 14 or 12awg I can get the pricing for that as well.
And there is also 3:1 Black and Red heat shrink tubing from 1/8" all the way up to 1-1/2"





post edited by ZachA - 2010/02/24 09:22:37


#32
Martin S
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Re:[Guide] Make and sleeve your own extension cables! 2010/02/16 18:46:32 (permalink)
Thanks for posting. I'll definitely be contacting you when I need some more wire!
#33
ZachA
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Re:[Guide] Make and sleeve your own extension cables! 2010/02/20 23:51:28 (permalink)
Just out of curiousity where did you get your Industrail hair dryer at?? lol

I ordered everything I needed today to re-wire my whole PSU and should have the goods by Thursday
 
 
4 x Connectx™ T-SATA Female (punch down) - Black (ACR-CB8201) Cap Type End Cap $3.96
1 x Sunbeamtech Power Supply Modding Tool Kit (SB-TOOLKIT) $19.99
5 x Connectx™ Molex 4pin Male Pins, GOLD-plated - 4 Pack (ACR-CB8119) $2.45
5 x Connectx™ Molex 4pin Female connector housing - Black (ACR-CB7525) Molex Pins No Molex Pins $1.95
2 x Connectx™ 6-Pin PCI Express connector housing - Black (ACR-CB4234) $1.58
2 x Connectx™ ATX 24-pin Male connector housing, Black (ACR-CB1219) Molex Pins No Molex Pins $1.98
50 x 0.125 (1/8") PET Cable Sleeving (PET1/8) Sleeve Color Black $14.50
10 x Pro Male 3-Pin Fan Pins - 3 Pack (PINS-4M-PRO) $3.90
5 x Connectx™ Molex 4pin Female Pins, GOLD-plated - 4 Pack (ACR-CB8102) $2.45
10 x Female 3-Pin Pins - 3 Pack (PINS3P) $2.90
5 x Connectx™ Male Molex Housing Black (ACR-CB8539) Molex Pins No Molex Pins $1.95
10 x Connectx™ Female 3-Pin Fan Housing Black (ACR-CB9031) Molex Pins No Molex Pins $3.90
10 x Connectx™ ATX 24 pin Female Pins, GOLD-plated - 24 Pack (ACR-CB8133) $39.90
3 x Connectx™ ATX 20+4-pin Female connector housing, Black (ACR-CB1202) Molex Pins No Molex Pins $3.87
10 x Connectx™ T-SATA Female (punch down) - Black (ACR-CB8201) Cap Type Pass-through Cap $9.90
2 x  Connectx™ PCI-Express 2.0 - 8-pin Female connector housing, Black (ACR-CBXXXX) Molex Pins No Molex Pins $3.98
2 x Connectx™ ATX 8-pin Female connector housing, Black (ACR-CB0618) Molex Pins No Molex Pins $1.58
8 x Connectx™ Low Profile Molex Connector - Punch Down with Cap - Black (ACR-CB8492) Cap Type Pass-through Cap $7.92
10 x Pro Series Male 3-Pin Fan Housing with Hood - Black (CX-M3PIN-BK) Molex Pins No Molex Pins $9.90
4 x Connectx™ Low Profile Molex Connector - Punch Down with Cap - Black (ACR-CB8492) Cap Type End Cap $3.96
50 x 0.125 (1/8") PET Cable Sleeving (PET1/8) Sleeve Color Red $14.50
15 x Connectx™ ATX Male Pins, GOLD-plated - 4 Pack (ACR-CB31021) $6.75
1 x Deluxe Molex Hand Crimp Tool (CRIMPER-DX) $24.95
20 x 0.25 (1/4") PET Cable Sleeving (PET1/4) Sleeve Color Cobra (Red/Black Criss Cross) $11.80
My total came out to be right about $200 for everything, I plan to reuse connecters from my PSU cables that plug into the PSU itself
post edited by ZachA - 2010/02/20 23:59:17


#34
Martin S
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Re:[Guide] Make and sleeve your own extension cables! 2010/02/21 13:12:18 (permalink)
ZachA

Just out of curiousity where did you get your Industrail hair dryer at?? lol

I ordered everything I needed today to re-wire my whole PSU and should have the goods by Thursday
 
 
4 x Connectx™ T-SATA Female (punch down) - Black (ACR-CB8201) Cap Type End Cap $3.96
1 x Sunbeamtech Power Supply Modding Tool Kit (SB-TOOLKIT) $19.99
5 x Connectx™ Molex 4pin Male Pins, GOLD-plated - 4 Pack (ACR-CB8119) $2.45
5 x Connectx™ Molex 4pin Female connector housing - Black (ACR-CB7525) Molex Pins No Molex Pins $1.95
2 x Connectx™ 6-Pin PCI Express connector housing - Black (ACR-CB4234) $1.58
2 x Connectx™ ATX 24-pin Male connector housing, Black (ACR-CB1219) Molex Pins No Molex Pins $1.98
50 x 0.125 (1/8") PET Cable Sleeving (PET1/8) Sleeve Color Black $14.50
10 x Pro Male 3-Pin Fan Pins - 3 Pack (PINS-4M-PRO) $3.90
5 x Connectx™ Molex 4pin Female Pins, GOLD-plated - 4 Pack (ACR-CB8102) $2.45
10 x Female 3-Pin Pins - 3 Pack (PINS3P) $2.90
5 x Connectx™ Male Molex Housing Black (ACR-CB8539) Molex Pins No Molex Pins $1.95
10 x Connectx™ Female 3-Pin Fan Housing Black (ACR-CB9031) Molex Pins No Molex Pins $3.90
10 x Connectx™ ATX 24 pin Female Pins, GOLD-plated - 24 Pack (ACR-CB8133) $39.90
3 x Connectx™ ATX 20+4-pin Female connector housing, Black (ACR-CB1202) Molex Pins No Molex Pins $3.87
10 x Connectx™ T-SATA Female (punch down) - Black (ACR-CB8201) Cap Type Pass-through Cap $9.90
2 x  Connectx™ PCI-Express 2.0 - 8-pin Female connector housing, Black (ACR-CBXXXX) Molex Pins No Molex Pins $3.98
2 x Connectx™ ATX 8-pin Female connector housing, Black (ACR-CB0618) Molex Pins No Molex Pins $1.58
8 x Connectx™ Low Profile Molex Connector - Punch Down with Cap - Black (ACR-CB8492) Cap Type Pass-through Cap $7.92
10 x Pro Series Male 3-Pin Fan Housing with Hood - Black (CX-M3PIN-BK) Molex Pins No Molex Pins $9.90
4 x Connectx™ Low Profile Molex Connector - Punch Down with Cap - Black (ACR-CB8492) Cap Type End Cap $3.96
50 x 0.125 (1/8") PET Cable Sleeving (PET1/8) Sleeve Color Red $14.50
15 x Connectx™ ATX Male Pins, GOLD-plated - 4 Pack (ACR-CB31021) $6.75
1 x Deluxe Molex Hand Crimp Tool (CRIMPER-DX) $24.95
20 x 0.25 (1/4") PET Cable Sleeving (PET1/4) Sleeve Color Cobra (Red/Black Criss Cross) $11.80
My total came out to be right about $200 for everything, I plan to reuse connecters from my PSU cables that plug into the PSU itself


Heat gun is $20 at Home Depot, it's in the paint aisle. Lmk how it turns out! 
#35
boogiebear
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Re:[Guide] Make and sleeve your own extension cables! 2010/02/27 20:38:25 (permalink)
can someone link me to where i can buy those pins and connectors? i cant find them anywhere
thanks








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Martin S
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Re:[Guide] Make and sleeve your own extension cables! 2010/02/27 20:42:15 (permalink)
.
post edited by Crys1s_Gam3r - 2010/05/16 11:13:02
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ZachA
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Re:[Guide] Make and sleeve your own extension cables! 2010/02/27 20:46:00 (permalink)
Crys1s_Gam3r

Pins at Newark.com, molex part # 38000038 and 38000040
Connectors from AC Ryan, distributed through frozencpu/performance-pcs


Performance Pc's has EVERYTHING you need


#38
boogiebear
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Re:[Guide] Make and sleeve your own extension cables! 2010/02/27 22:47:16 (permalink)
1 question. can i use the connectors that came with my power supply after i take the pieces out? or do i HAVE to buy new ones?








#39
ZachA
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Re:[Guide] Make and sleeve your own extension cables! 2010/02/27 23:27:32 (permalink)
boogiebear

1 question. can i use the connectors that came with my power supply after i take the pieces out? or do i HAVE to buy new ones?


you can use the ones you have, just make sure to be very carfully when you remove the connecters from the pins...


#40
klutzy
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/08 12:51:33 (permalink)
Crys1s_Gam3r

Thanks guys

edit: lol thanks jingiko!

Jeffro:


What model is this one?  looks like the HT1000, but I wasn't sure. 


  

#41
Martin S
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/08 13:06:27 (permalink)
You're correct, it's the HT1000. Nothing fancy but it works fine.
#42
enkay
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/08 17:32:23 (permalink)
thx for this
#43
mcochris
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/20 22:48:28 (permalink)
Nice work.  I personally prefer Teflon insulated wire - it's much tougher, can take a lot more heat, and has a nicer look & feel to it than PVC insulated wire.  On the downside, it's expensive, harder to strip, and not a flexible.  The conductors in Teflon insulated wire are also silver-plated and conduct a little better than plain copper.  I crimp and solder (Metcal) my connections, and the Teflon doesn't burn/melt like PVC.  I also like to use hot melt glue in some connector sockets to further secure the connectors and help the pins stay aligned.  I also find fiberglass cloth wire sheathing has a much nicer look and feel to it than plastic sheathing.  Fiberglass cloth is non-shiny, very flexible, completly opaque, and can take much more heat then plastic.  It's doesn't expand, but I like that.  I also recommend polyolefin heat shrink tubing instead of PVC.  I been doing my own cabling for years.

EVGA X58 E756 (Micro), BIOS 51, i7 920 D0 batch 3945A939, 3x2G Mushkin Redline, Heatkiller 3.0 LT, Swiftech MCR320, MicroRes, MCP655, MSI 8400GS, Corsair HX850, WD 300G raptor, Win 7/64 Ultimate
#44
seth89
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/21 10:52:57 (permalink)
hey this is a great guide. it will help me a lot when i do my fans.

thank you.


#45
Martin S
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/22 15:13:26 (permalink)
Thanks for all the feedback.

mcochris: Interesting info, thanks. I'll look into it when I buy more wire.
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shawnoen
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/26 12:29:16 (permalink)
I need a spool of black 18awg. Is it silver multistrand like Corsair uses on their power supply cables?
#47
stephen92
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/26 17:47:02 (permalink)
I thought this thread was stickied?

CPU:Q6600 @ 3.15Ghz Coolermaster V6
GPU: EVGA 560 Ti
RAM: 4GB G.Skill PI Black
Mobo: EVGA 680i LT SLI
HD: 1TB WD Caviar Black, 150Gb WD Velociraptor Win 7 Professional 64, 2x1TB Seagate Barracudas in RAID 1
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PSU: Coolermaster Silent Pro Gold 1200W
#48
Martin S
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/26 18:05:41 (permalink)
Shawnoen: PM replied

drdoomuzi4u: It was . When the DIY guide index was put up, this got taken down.
#49
qzwfcj
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/26 20:33:32 (permalink)
look nice
#50
Martin S
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/26 20:38:28 (permalink)
Thanks. Here's some more pics of extensions I've done:













#51
wizpug
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/29 15:52:15 (permalink)
this is awesome. thank you for this guide!

eVGA 680i A1 - XFX P32 BIOS
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#52
just a noob
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/29 16:37:13 (permalink)
If you don't mind me asking, what is the length of the heatshrink on those extensions? And how far up on the pin is the heatshrink on?
#53
mcochris
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/29 17:59:51 (permalink)
Fantastic!  I especially like how you got the heatshrink to be so uniform in length and shrunken size.  I know that's hard to achive!  I'm not a fan of the plastic sleeving, I've mentioned the fiberglass before.  But that's a personal thing.  It kinda buldges up near the connector on some of thoses pics.  That's just the nature of the material when bent, not any dings on your excellent craftsmanship.

You may want to experiment with putting some hot melt glue in the cable end of connector wells.  The glue hides the hole and physically/visually mates the connector to the individual cables.  If you overfill the conenctor hole a little, that can look good.  The glue bulges up a little and looks like the cable is molded to the connector.  I've used this technique on 4-pin molex conenctors and it worked well.  It also helped keep the molex pins centered, I was always having trouble mating connectors becuase the pins didn't line up.  You have to mate the M/F conenctors prior to adding the glue so the the pins are aligned and the glue does not make it ways into an areas that would prevent future connector mating.

I used hot melt because it cured quickly and was thick so it didn't flow much.  If the glue is too fluid (e.g. cheap superglue), it may flow down into the contact pins/sockets.  It worked on the 4-pin molex connectors, but the ATX and PCI connectors may have smaller holes and you may not be able to inject glue into the connector wells.  I used to just stick the point of my glue gun it each of the four corners on each connector well (with wire inserted) and inject some glue.  As the glue cured it would wrap itself around the wire and sink a bit into the well.  When it dried, it looked great.  It worked better than I expected.  I never experienced any problems with the "glued" connectors.

For example, on those PCI power connectors pics you provided, you can see where the heat shrink does not completely hide the transition from sleeving to pin.  The glue trick could hide that.  And it would keep the pins from moving around, so they would always be centered in the connector well, no matter how the cable was flexed.  Like soldiers standing in formation.

Anyway, free ideas, take 'em or leave 'em.  I looked for an sample of my "handy work", but I didn't make that many (it's takes alot of time) and I couldn't find one that's not installed.  If you provide a pay-for service, please PM me.  Thanks again for the wonderful pics!

EVGA X58 E756 (Micro), BIOS 51, i7 920 D0 batch 3945A939, 3x2G Mushkin Redline, Heatkiller 3.0 LT, Swiftech MCR320, MicroRes, MCP655, MSI 8400GS, Corsair HX850, WD 300G raptor, Win 7/64 Ultimate
#54
Martin S
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/29 18:47:02 (permalink)
wizpug

this is awesome. thank you for this guide!


Thank you, and you are most welcome! I'd love to see pics of your results.

just a noob

If you don't mind me asking, what is the length of the heatshrink on those extensions? And how far up on the pin is the heatshrink on?


The heatshrink is 0.5" exactly:




Feel free to ask more questions

mcochris

Fantastic!  I especially like how you got the heatshrink to be so uniform in length and shrunken size.  I know that's hard to achive!  I'm not a fan of the plastic sleeving, I've mentioned the fiberglass before.  But that's a personal thing.  It kinda buldges up near the connector on some of thoses pics.  That's just the nature of the material when bent, not any dings on your excellent craftsmanship.

You may want to experiment with putting some hot melt glue in the cable end of connector wells.  The glue hides the hole and physically/visually mates the connector to the individual cables.  If you overfill the conenctor hole a little, that can look good.  The glue bulges up a little and looks like the cable is molded to the connector.  I've used this technique on 4-pin molex conenctors and it worked well.  It also helped keep the molex pins centered, I was always having trouble mating connectors becuase the pins didn't line up.  You have to mate the M/F conenctors prior to adding the glue so the the pins are aligned and the glue does not make it ways into an areas that would prevent future connector mating.

I used hot melt because it cured quickly and was thick so it didn't flow much.  If the glue is too fluid (e.g. cheap superglue), it may flow down into the contact pins/sockets.  It worked on the 4-pin molex connectors, but the ATX and PCI connectors may have smaller holes and you may not be able to inject glue into the connector wells.  I used to just stick the point of my glue gun it each of the four corners on each connector well (with wire inserted) and inject some glue.  As the glue cured it would wrap itself around the wire and sink a bit into the well.  When it dried, it looked great.  It worked better than I expected.  I never experienced any problems with the "glued" connectors.

For example, on those PCI power connectors pics you provided, you can see where the heat shrink does not completely hide the transition from sleeving to pin.  The glue trick could hide that.  And it would keep the pins from moving around, so they would always be centered in the connector well, no matter how the cable was flexed.  Like soldiers standing in formation.

Anyway, free ideas, take 'em or leave 'em.  I looked for an sample of my "handy work", but I didn't make that many (it's takes alot of time) and I couldn't find one that's not installed.  If you provide a pay-for service, please PM me.  Thanks again for the wonderful pics!


Thank you Chris! You seem to be very knowledgeable in this field. Interesting idea with the hot glue, I'll definitely have to try that out someday. My only gripe is in it's advantage -- it would be near impossible to remove the wire, when I needed to. Just today, for example, I got some cables I back from a customer, to "adapt" them to different PSU (modular cable, not extension). Basically just rewiring, but it would have been very frustrating if they were held in with glue.

BTW - I've also been experimenting with methods to ease the sleeve/connector transition. You can't see it in the last pic because of the angle, but the sleeve actually goes about 0.5mm into the connector. The result is a clean, straight, no bulge entry. I would take some better pics but it was shipped out this morning (enjoy eppopipe! ).

Once you get to 50 posts, check out my FS thread (linked in sig image) -- pictures of every cable I've ever sold are there.

-Martin aka Crys1s
#55
just a noob
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/29 18:53:54 (permalink)
Thank you!(I personally don't like it when people use what I consider to be too much heatshrink[like an inch]). You don't have any issues with it holding, do you?
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Martin S
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/29 18:56:21 (permalink)
just a noob

Thank you!(I personally don't like it when people use what I consider to be too much heatshrink[like an inch]). You don't have any issues with it holding, do you?


I agree 100%.

EDIT: Ah I see what you mean now. I did have one wire that needed to be shipped back to me and reshrunk, that's out of over 700 wires though so I think the odds are in my favor.
post edited by Crys1s_Gam3r - 2010/03/29 19:12:14
#57
just a noob
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/29 19:13:12 (permalink)
Like, when you go to bend the cable to hide it behind the motherboard tray, the heatshrink won't loose its grip, will it(I suppose this means no hanging from the psu sleeving either then? )
#58
Martin S
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/29 19:15:46 (permalink)
just a noob

Like, when you go to bend the cable to hide it behind the motherboard tray, the heatshrink won't loose its grip, will it(I suppose this means no hanging from the psu sleeving either then? )


No, it's very secure. Just make sure you heat it long enough, to maximize the amount it shrinks/"grip"
#59
just a noob
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Re:[Guide] Make and sleeve your own extension cables! 2010/03/29 19:17:32 (permalink)
Alright then, thanks for that info, it should come in very handy when I get a new psu/sleeving(from MDPC-X of course)
#60
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