DIY Power Cords

nc42acc

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Do you solder the bare wire ends of the power cord before you insert them into the AC plug or leave bare? My concern leaving bare would be tarnish and deterioration. I remember seeing a AudioQuest video showing someone terminating a power cord and they used what looked like a paste on the bare wire ends before they were clamped into the AC plug. Maybe a silver or copper paste?
 
Assuming that you are using copper wire as the conductor... In a well designed AC plug, the mechanism firmly securing the stripped wire ends inside the plug should provide full contact surface area whereby oxidation would not a be problem. Be sure to strip off only as much of the dielectric as is necessary for the connection. That being said, one can always "tin" the exposed wire with solder to prevent any oxidation if you are concerned. There are plenty of internet videos demonstrating this technique. (Note: A few specialty wires are manufactured as Litz conductors where each individual copper strand in the conductor is coated with an insulating lacquer. This wire requires the stripped ends be tinned before any connection is made.)

Alternatively, one can use tinned-copper wire conductors where the individual copper wire strands have been plated with a very thin coating of tin. Here, the "tinning" has already been done for you. There are a few power cable makers using this type conductor wire with excellent results.
 
Hi Marty,

Don't tin the wires, use crimp sleeves / ferrules to contain stranded wire conductors that will then be screwed down in the terminal block/connector (as described in the link above). I've been doing it this way for many years now and it creates a nice secure connection and also encapsulates the individual strands of bare copper conductors to minimize oxidation.

Another option is to use small spades like the Furutech FP-209. Then you can solder the conductor to the spade and insert the spades' forks to clamp down inside the connector body.
 
A good read and opinions...

Great information; thanks for posting the link.

While thermo-mechanical creep deformation of soldered connections is an important issue in microelectronics manufacturing, it is interesting to learn that it might be a consideration in the type connection discussed here where the solder is not used to make/secure the actual connection.

Certainly an issue to be mindful about.
 
As 'Mike' just wrote. Never solder/tin the end of a wire under a screw terminal. Over time the solder will cold flow and the terminal will loosen!
What you can do however is:
Strip about 3/16 inch of insulation.
Solder/tin the very end of the wire.
Strip about 1/2 inch more insulation.
Then center that bare wire under the screw terminal.
 
Another great idea. I am going to try the small spade technique and also try using a conductive paste and ferrules too. I have lots of time and materials to dabble away.

As 'Mike' just wrote. Never solder/tin the end of a wire under a screw terminal. Over time the solder will cold flow and the terminal will loosen!
What you can do however is:
Strip about 3/16 inch of insulation.
Solder/tin the very end of the wire.
Strip about 1/2 inch more insulation.
Then center that bare wire under the screw terminal.
 
Yes, ferrules are a great way to go, especially if you are doing a lot of connections. Or if it's fine strand rather than course strand wire.
Ferrules are very common in industrial or military applications.
 
Furutech FI-50M connectors. Furutech FP-S55N cable. Made for my ARC REF5SE

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That looks nice.
Did you connect the shield at the male plug end to act as an RFI/EMI drain?
Different schools of thought dictate one way or another on shields.
 
I would connect the shield only at the hi-fi component end of the cord. That way it acts as an extension of the component's chassis (which is also the more important shield). I don't know if 'UL' would be happy with this in a commercial cord.
 
I asked Furutech how to connect the outer braid and this is what they told me.

I would connect the shield only at the hi-fi component end of the cord. That way it acts as an extension of the component's chassis (which is also the more important shield). I don't know if 'UL' would be happy with this in a commercial cord.
 
Considering the shield gets spliced with the ground wire, why would it make any difference if its spliced at the plug or IEC? Its all the same is it not?

I would connect the shield only at the hi-fi component end of the cord. That way it acts as an extension of the component's chassis (which is also the more important shield). I don't know if 'UL' would be happy with this in a commercial cord.
 
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