[Drake] Fabricating the two-pronged plug

[Thomas Beltran]

Drakeians

I fabricated my own two-pronged plug that goes into the AC-4 supply.
Someone sent me a private email asking for the dimensions, and I lost
(accidently deleted)the email.  So here goes.

I used a piece of plexiglass, 3/8" thick, 3/4" wide and 1 1/8 inches =
long.
Cut two pieces of 3/32" drill-rod 1 1/8" long.  I drilled two holes
lengthwise, all the way through the plastic blank, that were the proper
spacing for the plug (with an unplugged supply, I inserted the two 3/32"
drill rod pieces into the power supply plug and measured the distance - =
C to
C is 3/8" - you might want to verfiy that this is correct).

Next, I drilled two slightly larger holes on one side, 3/8" deep, =
enlarging
the previously drilled holes.  The holes need to be enlarged because =
this is
where the wires are soldered to the drill rod.  To summarize, there are =
two
lengthwise holes properly spaced, 3/32" in diameter, but on one end, =
each is
enlarged 3/16".  Then, on the end with the prongs (the business end), I
sanded off the corners of the plastic, just for looks.

I found a nice heavyduty patch-cord, and cut one connector off, =
soldering
one wire to each piece of drill rod.  Then I pushed each drill rod into =
the
plexiglass from the side with the enlarged hole, and super-glued it.
Finally, I used some silicone sealant and liberally applied it to the =
back
of the plug, and onto about 1 1/2" of the wire, as a strain relief.
Incidently, this has worked very well - that silicone stuff is very =
tough.

I have a well-equiped shop, and it took about 25 minutes to make, after =
I
decided what to do.  I think one would need a drill press and use very =
slow
speed to drill the holes.  Drilling fast in plexiglass can slightly melt =
the
plastic, which grabs, and can throw the work.  It is only the Silicone =
that
makes it look not so pretty, but it works very well.  Tom W6EIJ



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