[Drake] Fabricating the two-pronged plug

Thu May 6 20:08:09 EDT 2004

Why not just do what drake did.....
A small square of aluminum with a hole in the middle.
Put a phono jack in the hole.
Problem solved.
PS...Drake offered this as an upgrade kit.
I have the details in one of my Drake manuals.
...Dave
----- Original Message ----- 
From: "Thomas Beltran" <[email protected]>
To: <[email protected]>
Sent: Thursday, May 06, 2004 2:52 PM
Subject: [Drake] Fabricating the two-pronged plug

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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