[Milsurplus] Repairing "Command Set" Male Connectors.

[Peter Gottlieb]

Very interesting.  I have some connectors of this typi which have gold plated  
leaves and pins.  When did they do that?  I can't remember what radios I got 
them from.  I guess I should save them.

Peter

On 10/6/2014 11:13 PM, David Stinson wrote:
> 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
>
> ______________________________________________________________
> Milsurplus mailing list
> Home: http://mailman.qth.net/mailman/listinfo/milsurplus
> Help: http://mailman.qth.net/mmfaq.htm
> Post: mailto:Milsurplus at mailman.qth.net
>
> This list hosted by: http://www.qsl.net
> Please help support this email list: http://www.qsl.net/donate.html
>