Headers plugs and sockets

[giftiger_wunsch]

Hi guys,

I recently purchased some PCB-mount header plugs and some molex socket housings and crimp terminals, both 2.54mm pitch, and unfortunately discovered that they do not fit together, and that the site from which I ordered these components does not appear to have suitable connectors which can mate with either of the products I purchased.

The PCB-mount header plugs are 36-way, 2.54mm pitch headers with 0.64mm² pin cross sections. The molex sockets' holes were too large to form an adequate connection, but when I checked the data sheet they also claimed to be for a 0.05mm² pin, so I can only assume that the data sheet is incorrect.

I'm mainly interested in finding single-pin and/or two-way wire-mounted header sockets which can fit over a 2.54mm pitch header with 0.64mm² pins; preferrably from a cheap UK source, and especially sockets with as little excess trim as possible (the molex housings would have interrupted adjacent pins even if they had fit).

I have included photos of one of the 2.54mm-pitch 0.64mm² headers, along with a similar header socket to the type I am looking for.


34-way 2.54mm-pitch 0.64mm² PCB-mount header:

**broken link removed**


Looking for a 2way (or especially, single-pin) socket similar to this one:


**broken link removed**


Thanks in advance for any help rendered.

 

[jpanhalt]

Finding connectors can be a pain. I use what you describe, but couldn't find them in my old orders going back 2 years.

For single connectors, I have been unable to find a housing. I simply crimp a female socket on the wire and cover with heat shrink. That works well for an isolated pin on a board. I don't think I would trust it for a hanging cable, unless you put heat shrink over both the pin and socket together.

For multiple crimp contacts (i.e., excluding IDC), I used to use Berg #48234-000 from Allied Electric. Allied also had the matching housings, but last time I looked, Berg had disappeared. It may now be FCI Berg-Con or something. That is how it seems to be listed at Mouser. Find the female pin you like, then the housing to match. There is a barb and an indent type of pin. You show the indent type in which a finger on the housing snaps into an indent on the pin/socket. I personally prefer the indent over the barb type. If you only need a few, hobby shops sell 2 and 3 conductor connectors for servo and battery connections.

John

 

[Nigel Goodwin]

If you check my PIC tutorial hardware pages, I used Molex connectors on them - ten way ones. They plug directly on the PCB pins you pictured above, which were what I used before I ordered the correct Molex PCB male sockets.

The RS Component part numbers are listed in the tutorial.

 

[jrz126]

I buy mine from futurlec.com
Headers (Halfway down the page)

I found its cheaper to just buy the 20-pin version and cut it to whatever length I need.

 

[giftiger_wunsch]

Thanks jrz, that's exactly the sort of page I was looking for... overseas delivery will probably be expensive though. Unfortunately most of the UK suppliers I've looked at don't seem to have such an extensive range of headers.

 

[3v0]

Most Futurlec orders are $5 US for shipping.

I have been told Thailand has about the least expensive postal fee's in the world.

 

[Nigel Goodwin]

Thanks jrz, that's exactly the sort of page I was looking for... overseas delivery will probably be expensive though. Unfortunately most of the UK suppliers I've looked at don't seem to have such an extensive range of headers.

They might have them, but it's not set out anywhere near as well, that Futurelec page is beautifully simple, everything you need on one page.

 

[giftiger_wunsch]

It may be worth simply getting them shipped from america, given the issues I've had finding them so far. The prices seem reasonable and they all seem to be a standard 0.025" (0.64mm) square pin, which is what was needed.

Thanks for the help guys.

 

[HarveyH42]

I ordered header connectors from Futurlec a while ago, would strongly suggest getting the tool to crimp them. Just got the tool about a month ago, and it's so much easier. Don't remember where I got it off hand, it was in a sales flier, and cheap, so grabbed one. Can't believe how much time I wasted making cables with pliers...

 

[giftiger_wunsch]

Probably won't use the tool frequently enough to be worth buying, especially as I've heard they're usually quite expensive. I was told in another thread that soldering the connections should be fine, just take longer. I'll need a fair bit of practice with soldering before attempting to solder the headers themselves, so I'll probably simply solder the connectors.

 

[HarveyH42]

Probably won't use the tool frequently enough to be worth buying, especially as I've heard they're usually quite expensive. I was told in another thread that soldering the connections should be fine, just take longer. I'll need a fair bit of practice with soldering before attempting to solder the headers themselves, so I'll probably simply solder the connectors.

This is the one I bought...

Circuit Specialists Inc. - D-SUB Crimping Tool (HT-213)

Got it for $7.99 (on sale), still well worth $10.00. Just insert the open portion of the crimp, slide in the striped wire, gentle squeeze. Those little pins are tough to handle , well you'll see what I mean...

 

[jrz126]

Wow Harvey, thats an amazing deal. I've been wanting to order a soldering iron for work, looks like I'll have to sneak this into the order.

 

[jpanhalt]

That crimper is also sold by Radio Shack (Radio Shack: D-Sub Pin Crimper, Model: 276-1595) for about $10. I have been using one for several years, and it works. It is possible to over-crimp with it and distort the contact.

Recently, I found a "commercial type" crimper with compound leverage at Servo City (Kansas, USA) for about $20. That is really cheap compared to the AMP and other industrial crimpers. It appears to be a Chinese copy, so QC might be a problem. But so far, I am very satisfied with the one I got. I tried and could not make it distort a typical indent-type contact.

Here is the link to the catalog page:

**broken link removed**

John

 

[HarveyH42]

All I know, is it was a major pain trying to do these tiny, delicate pins with pliers an tweezers. Kept dropping them, mangling them, and usually glad my handy work would be hidden in the housing. I've only done one 16 pin LCD cable with the tool, both ends, and not one bad crimp, none of the previous issues. Not saying its the best tool on the market, would know, its the first one I've used. Was never big on making custom cables, but this tool takes a lot of the pain away. As mentioned before, there are several ways to avoid using special tools, and it will probably show (like most of mine), but what ever works. Was just hoping to spare you the aggravation I endured, share the experience...

 

[giftiger_wunsch]

Thanks Harvey; if I get the urge to throw the cable across the room I'll look for a crimping tool