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Low Cost DIY Interconnect Details, a How To

My version of very low cost DIY interconnects.

- Gepco 61801EZ Cable. Ordered directly from Gepco, in bulk quantity ($0.10/ft)
- Streetwires RCA ends from ebay. (seller = "trucktunes") (50 for $15 + ship)

also:

- 1/4" (expanded) adhesive lined heat shrink
- 1/2" (expanded) adhesive lined heat shrink
- 1/4" Expandable sleeving (aka. "Techflex")

Tools:
- soldering iron (with solder, duh!)
- utility knife
- wire cutters/strippers
- needle nose pliers (for crimping)
- ruler
- butane lighter (for shrinking tubing)
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300 ft. of Gepco 61801EZ = $30. Yep, that's $0.10/ft.
300 ft. of Gepco 61801EZ = $30. Yep, that's $0.10/ft.		 Streetwires RCA ends on Ebay. 50 pcs. for $15.
Streetwires RCA ends on Ebay. 50 pcs. for $15.		 RCA ends taken apart.
RCA ends taken apart.		 Expandable sleeving (Techflex) and adhesive lined heat shrink
Expandable sleeving (Techflex) and adhesive lined heat shrink
Back side of packages.
Back side of packages.		 Tools/supplies for the job. Not shown: disposable butane lighter, needle nose pliers.
Tools/supplies for the job. Not shown: disposable butane lighter, needle nose pliers.		 First, cut the Gepco (or whatever signal cable) to length.
First, cut the Gepco (or whatever signal cable) to length.		 Take your utility knife and score all around the outer jacket of the cable. Not too deep; just make a line like this.
Take your utility knife and score all around the outer jacket of the cable. Not too deep; just make a line like this.
Gepco is great because all you have to do after scoring is.. bend it one way....
Gepco is great because all you have to do after scoring is.. bend it one way....		 and then bend it the other way...
and then bend it the other way...		 Insulation pulls off to reveal two conductors and a drain wire (shield). Strip the two inner wires with strippers.
Insulation pulls off to reveal two conductors and a drain wire (shield). Strip the two inner wires with strippers.		 On the SOURCE end, I twisted drain and black together as shown. On the receiving end, I cut the drain wire completely off.
On the SOURCE end, I twisted drain and black together as shown. On the receiving end, I cut the drain wire completely off.
Next, I folded the red (signal) wire over to double the wire density, and then trimmed the ground down to a shorter length.
Next, I folded the red (signal) wire over to double the wire density, and then trimmed the ground down to a shorter length.		 Insert the cable to get red inside the center conductor, ground to the outside of the RCA
Insert the cable to get red inside the center conductor, ground to the outside of the RCA		 Closer view of the center conductor. Folding over the wire fills the center pin hole better...
Closer view of the center conductor. Folding over the wire "fills" the center pin hole better...		 Next crimp around the outside jacket to hold everything together.
Next crimp around the outside jacket to hold everything together.
Ground side; we're ready to solder.
Ground side; we're ready to solder.		 Solder the center conductor..
Solder the center conductor..		 Solder the ground.
Solder the ground.		 Cut your heat shrink to length: I used 1.5 length of the 1/4, 1 length of the 1/2
Cut your heat shrink to length: I used 1.5" length of the 1/4", 1" length of the 1/2"
Slip the heat shrink over and seal it up using the butane lighter.
Slip the heat shrink over and seal it up using the butane lighter.		 Slip the RCA end over and screw it on. Make one more just like this so you have a stereo pair. DON'T PUT THE OTHER END ON YET!
Slip the RCA end over and screw it on. Make one more just like this so you have a stereo pair. DON'T PUT THE OTHER END ON YET!		 Next, slip the two pieces of 1/2 heat shrink then the expandable sleeving over the pair of wires. (from the non-connector end)
Next, slip the two pieces of 1/2" heat shrink then the expandable sleeving over the pair of wires. (from the non-connector end)		 Slip the last two pieces of 1/4 heat shrink and RCA ends on BEFORE soldering this side. Double and triple check it!!
Slip the last two pieces of 1/4" heat shrink and RCA ends on BEFORE soldering this side. Double and triple check it!!
Pull the 1/2 heat shrink onto the sleeving, get the sleeving and wires positioned properly. Shrink one end of the sleeving.
Pull the 1/2" heat shrink onto the sleeving, get the sleeving and wires positioned properly. Shrink one end of the sleeving.		 Pull the sleeving taught and heat shrink the remaining end to complete. If you positined evertything properly all's good!
Pull the sleeving taught and heat shrink the remaining end to complete. If you positined evertything properly all's good!		 Relish your new interconnects before you hook them up to your cool new processor. :D
Relish your new interconnects before you hook them up to your cool new processor. :D
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