[ARC5] Repairing "Command Set" Male Connectors.

[David Stinson]

It's taken me some time to get this one done.
Sorry for the delay.
Posting this to other lists as it may be applicable 
to other connectors on other radios.
-----------------------------------------------------

Our "Command Sets" are getting old and it's not unusual
to lose the "banana leaves" off one of the male 
connector pins.   To understand how the connectors
are made,  take a look at this:
http://home.netcom.com/~arc5/connectors/IMG_3569.JPG
Each is a solid "donut" with a center pin and a tiny
smaller-diameter "post" sticking up from the top
of the pin.  There is a groove at the base between
the pin and side of the "donut."  The "banana leaves"
have a small hole in the end where they join.
The "banana leaves" are lowered over the post,
the ends of the "leaves" go into the groove
between the "donut" and the post and the tiny 
post at the top goes through the hole at the 
"banana leaf" junction point.  The post is then 
flattened to hold the leaves.
This flattened part of the post can metal-fatigue or
corrode, causing the leaves to fall off the post.

This can be repaired.  It takes a steady hand, 
a good light, some small tools, and PRACTICE.
You will break or lose some "leaves,"  
but fewer as you work with it.

Use a scraped male connector to harvest "leaves."
http://home.netcom.com/~arc5/connectors/IMG_3572.JPG
Using a small file, easy pressure and patience, you can 
remove the flattened part of the pressed post.
Once you think you have it mostly removed, grasp the 
"leaves" at the top near the junction point and attempt
to rotate them on the post.  If you have enough of the 
flattened post removed, the leaves will rotate, fatiguing the
thin remainder of the post and will eventually come free of it. 
http://home.netcom.com/~arc5/connectors/IMG_3573.JPG
This is the point where one can easily smash or break
the "leaves."  Practice and this will happen less often.

Using a soldering iron to tin the end of the vertical pin
and post.  Use a wet Q-Tip or cloth or something to 
wipe-away excess solder from the pin.  Excess solder
will run down into the leaves and make them ridgid,
which won't work.  Tin the junction of the "leaves"
and again remove excess solder.

Slide the "leaves" over the pin and seat them down
on the remains of the post, making sure the open end
of the "leaves" go into the groove in the "donut."
http://home.netcom.com/~arc5/connectors/IMG_3574.JPG
(I harvest "leaves" off bad male connectors just for this).
Once the "leaves" are seated well,
just touch the end of the pin with the iron and a 
tiny dab of solder.  Remove the iron and use the file
to remove any "flash."    Use the tweezers to press
the "leaves" and test that they are free and spring properly.

This will not be as strong as the original, but will work
and hold-up for at least a few connect/disconnect cycles.
I've fixed several and only had to re-do one of them.

This can also be used to "rescue" pins that have been
"solder-blobbed."

Hope this helps.
GL OM ES 73 DE Dave AB5S