Cable Asylum

Making Flavor 4 PCords...5/8" hose just fits...how to you also get the ground wire through???

68.5.214.42

Carl G

Hi all
Purchased 24 ft of Chris's Flavor 4 cable about 6 months ago, fits into air hose that is 5/8 inch in total diameter,,,however my male and IEC connectors only can squeeze in a max of 5/8" hose...how do you shoehorn in the ground wire which is supposed to go outside of the hose...yet be clamped to the connector...

thanks for your suggestions

Follow Ups:

RE: Making Flavor 4 PCords...5/8" hose just fits...how to you also get the ground wire through??? - ChrisVH 14:06:33 05/18/15 (0)
Hi, Carl. A DIY version of the Flavor 4 is easiest to make using connectors that will accommodate the girth. The Furutech FI-11, FI-25, FI-28, and FI-50's will handle this. WattGate (classic version), Marinco and Oyaide won't, without some modding of the connector.
I'd like to make it clear that the strain relief clamps must be cinched onto the hose, and not the cable jacket. It's an important part of the design.
If you are trying to terminate into WattGate (classic) or Oyaide connectors, you'll need to enlarge the rear of the backshell. I found a high-speed rotary tool works well (Dremel). The bit used is something like this: http://www.dremel.com/en-us/Accessories/Pages/ProductDetail.aspx?pid=9901 It gives you the ability to 'reach' deep enough into the backshell to carve out what you need to enlarge. Requires even pressure and a little finesse, and make sure you're wearing safety Goggles. Don't be too aggressive and take too much off at once, or you'll melt the plastic, and the fumes are quite nasty.
An additional item for the WattGate (Classic) is you'll need to slightly enlarge the entry holes for the wires. Any tool that will ream the excess plastic will work for OK this. Multiple options there...
If you're using techflex sleeving, it helps to secure it with some clear packaging tape. This works well, because it is slick/smooth, and prevents friction points from damaging the techflex when sliding over the hose. You can use two separate layers, each about 3/4" or so, and have them overlap. A little rubbing alcohol to act as a lubricant will allow you to glide the backshell onto the hose, and when you slide the backshell back onto the connector, you can trim away one of the 3/4" pieces of tape, and then use some heatshrink (about 2") to cover this area, for a nice, clean look. A little 1-1/2" shrink to finish over the connector and about 2-1/2 onto the cable body will complete it nicely.
Lastly, it's important to clamp the strain relief down so that the ground wire doesn't get 'pinched'.
I'll be publishing the full DIY Flavor 4 recipe soon, but it's essentially the same as the Flavor 2 - just subbing the star quad for the twisted pair, and a 10 AWG ground for the 12 AWG ground used in the Flavor 2.
Please let me know if you have any other questions.

There are two kinds of fools: one says, This is old, therefore it is good; the other says, This is new, therefore it is better.
- William Ralph Inge

Edits: 05/18/15
RE: Making Flavor 4 PCords...5/8" hose just fits...how to you also get the ground wire through??? - madisonears 20:18:30 05/17/15 (0)
Perhaps cut away a bit of the hose large enough to pass the ground wire just at the entrance to the plug. I don't think that will compromise the performance.

Peace.
Tom E

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