Hi Jeep - You might try Hot Glue.  I have used it to make female chassis connectors for the 4-5 pin connectors in the GRC-109 system and a BA-48 battery connector clone.  Molded molex females inside PVC pipe caps, filled with hot glue directly and also via side-holes.  It's a good insulator, flows well when very hot, resilient without cracking and can be dug out if necessary.  Worked fine in these cases:
http://www.n6cc.com/wp-content/uploads/P9290601.jpg
https://www.n6cc.com/wp-content/uploads/P9260257.jpg

Tim
N6CC

On Mon, Mar 24, 2025 at 5:45 AM Doran Platt via MRCA <mrca@mailman.qth.net> wrote:
I have had to make up a few connectors, primarily from open headers, vice from total scratch. I have been using JB Weld with good success.  However, when things are at close quarters, pin wise, the JB does not flow elll (cold flow) into the nooks and crannies.  So, what do you all use?  I visited H.D. and looked for something either JB or Gorilla that might be more fluid.  I bought a clear type but its not clear it will dry properly in a larger volume.  All the 2-part epoxy products are simply non-flowing. All suggestions appreciated.
Jeep K3HVG
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