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I got some extra Kimber braided power cables and am trying to DIY a powercord with a US Marinco power plug and IEC connector. Problem is I can't seem to get the stripped ends comfortably into the live or neutral points: too fat since each end has 8 "legs", would cutting off 2 or 3 of the 7 leads on each "leg" (to reduce the overall end size) sacrifice performance ? Thanks for your response !
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Follow Ups:
I have had very good results by removing the screw/clamp assemblies and soldering the wires directly to the blades themselves on the male plug. The IEC end is a bit more difficult to disassemble but the wires can be directly soldered to these connections as well.Need to add that the barrel cap(s) will not be reused. Proper wire dressing via heatshrink will be necessary.
Major increase in performance by doing this. U will need at least a 40 watt iron though.Cheers,
~kenster
Since the idea seems to be low impedance, you could use fatter wire still and terminate it with two plugs, and make DAMN SURE they're both wired the same and are polarized. If they're not wired the same it won't hurt your equipment, but it will make a first-rate circuit breaker tester.
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I would buy a better connector that can accept the larger wire. Everything else is a comprimise to some extent. I've comprimised before and gotten away with it. Just wanted to state I think it is a comprimise to trim off part of the wire or solder an extension that will fit etc.
just one idea. I would not strip off wire. I would solder a short length of 10 0r 12 gauge solid core copper wire to the end and then seal the termination of the two with a clear coat of lacquer. The solid core should easily fit.
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Or, you could solder a copper slug the same width and thickness as the plug's blades to allow the full count of wires to be used. If you can't solder these in place bend a short "L" foot at one end of the copper slugs and drill a hole in each foot so they can be secured to the plug by the screws intended for the line cord conductors to be connected to the plug. Then solder the full compliment of wires to the copper slugs. This will require that you get longer screws to secure the barrel of the plug and possibly an insulated addition to the plug's barrel as well. I would definitely NOT strip any of the wires from the linecord as that will lessewn the performance of the cord.
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You may want to either modify your current connectors so all the wires fit
in the Line and Neutral connection points, or use connectors like
the Furutech FI-11 series with larger double connection points.The upper right hand corner has an enlarged view of the larger
double connection points used to secure the wires.(Note FI-25 photo
used above)
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