Protecting Modular mic plugs from breakage

[KJ5XX]

If you have one of the newer rigs from Icom, Kenwood and others, you are probably familiar with the trend toward using modular (RJ45 type) jacks in place of the older, and sturdier 4, 6, and 8 pin connectors. Why are the rig manufacturers going away from something that not only worked but has been the standard for decades? Simple - cost.

Of course modular connectors are nothing new, they too have been around for decades. The difference is that the old style pin connector could be disconnected and re-connected many times, with no deterioration in performance. RJ45 type modular connectors were designed to be connected ONCE and left where they were connected. As a result they are commonly used in telecommunications cabling and Ethernet cables.

The problem with applying this type of connector to ham applications is that many times a mic may be connected, disconnected and re-connected as a rig is used for portable or other operation. Over time the clip weakens and eventually breaks.

If you've never tried putting on a modular jack, it can be very tricky!! One false move with a bad crimp and you can cost you big $$ in expensive rig repairs. The other issue is that even though the modular jacks in use by Icom and others "look" like RJ45 jacks - they're NOT. As a result, don't even try to use the kind of crimping tool they sell at Radio Shack - it just doesn't work. These jacks require specialized (and expensive) crimping tools and associated dies.

There is a solution that I've found that at least can help protect your modular jack and hopefully extend the life of it. These little modular jack protectors or boots slip or snap over the modular jack and protect it both while in use and when not.

There are really two types of these boots - "pre-assembly" which are commonly referred to as modular jack protectors or RJ45 "boots". The ones designed for putting onto an RJ45 connector AFTER it is connected to the mic cable are called "post-assembly RJ45 boots" (although they may go by other names as well)

Probably the easiest way to search for these on the web is to use the words "post assembly RJ45 boot" or "RJ45 snap-on boot"

Here are a few places I've found that sell these (you can easily see the split construction in some of these):

http://www.lindy.com/us/productfolder/06/60386/index.php

http://www.amazon.com/dp/B00006HO4L?smid=A3LJ5WMKNRFKQS&tag=cnet-ce-20&linkCode=asn

Why the rig manuafacturers don't put these on their mic cables is beyond me.

73,

[KI4ZSZ]

I read the article first on eham.net.

Pretty good tips. I am glad to see that the metal mod plugs are still in vogue for many of the HF recievers, but wish Icom and Yeasu would go back to them for the mobiles and such. I'm willing to pay 10-15 bucks extra for the cost of a good old standard metal plug...

[M0DSZ]

If you can't get the boots, heat-shrink tubing might help but it may also require a little tape to pad out the cable to greater thickness.

[K9YLI]

there are two types of plugs used in the phone business.
The ones for solid wire and for stranded wire.
You can't successfully swap them.
I have a multi-size crimper tool. about $30..

trick is to hold the wires lin the roper sequence between thumb and finger,
cut to length,and stuff in connector, with out letting go of the wire.
push to be sure all wires bottom out in the slots and color sequence is correct.
Biggest problem is the tools is made for right handed people.
I have to remember to invert it.

Right handed people look where they have been.
Left handed people look where they are going.

Just grab a pencil to prove it.

[wb9jtk]

Here are a few places I've found that sell these (you can easily see the split construction in some of these):
Both of those show 'not available online' or "out of stock".

Try here (http://www.secondhandradio.com/ShowAd.aspx?id=210), in stock and cheap shipping!

[WA7KKP]

The reason? Cheap. They cost about a quarter each, and far less than that in bulk. Much cheaper than the Jap metal mic connector, or the traditional 1/4" TRS phone plug or XLR connector.

You can either replace it with a REAL connector (space permitting), or just hardwire the cord into the radio. Then you have to worry about the cord breaking conductors right at the point it enters the radio.

Or you can invest in a bag of RJ-45 connectors and a crimper. Replace it when needed.

Gary WA7KKP