[ARC5] Those Cussed 1930s PL- Plugs

[David Stinson]

Tips concerning those big 1930s PL-series connectors
like the PL-61 and PL-64:

First- the Bakelite inserts absorb water and swell.
Some have swollen enough to split the metal 
outer shell.  If yours is stuck and will not come out
with gentle tapping as below, don't force it.
I've had good luck baking them in
an oven for an hour and then letting them cool.
It's been awhile so I don't remember the temp
I used- probably around 175 or even 200.
It stinks, so open some windows.  After that
all I've tried have come right out with a little "tapping."  
Put a woodend dowel through the back of 
the connector, up against the insert.
Tap gently with a hammer and it will 
usually break free and come out.

Second-  Those infernal locking clips, 
with the two short locking pins on them.  
I don't know who invented this abomination, 
but I hope that, in Purgatory, they made him reassemble 
about a million of them.  If you've ever worked
with one of these plugs, you know what I mean.
I hope I can describe this properly...
In order to put the plug back together easily,
you need a metal shim- a strip of thin, stiff
metal just wide enough to fit inside the slot
on the insert and at least a couple of inches long.
Longer would be better.  I have a strip from a 
relay burnishing tool that works well.
Fasten the shell (gently) in something to hold it
with the locking-key holes down.  
Install the locking clip, open end of the "V"
facing you.  Lay the shim on top of the clip.
Place the insert so the shim is in the key groove
of the insert.  The idea is that the shim, guided
by the groove in the insert, compresses the
locking clip as you push the insert in.
That's why it needs to be thin and stiff.
A piece of galvanized steel might work,
if it isn't too thick.
Gently push the insert home and pull out the shim.

Now cuss yourself  because you broke a wire
and you have to do it over again ;-)

73 Dave S.