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MISC

Stacked Poles

Not all of the TRRS connectors have tabs. Some of the connectors have 
stacked "poles" to solder to. Many of the steps for attaching them are 
the same, but the process is a bit different.

1

Prep the cable as covered previously. 

After you slide the barrel and heatshrink 

on to the cable (don't forget!), Place 

the connector onto the cable with the 

clamps making solid contact with the 

gathered shielding. The shielding needs 

to make physical contact with the clamp 

tab for proper shielding/grounding. 

3

After you get them all tinned, inspect 

your work. Make sure the plastic isn't 

covering up the tinned soldering poles. 

Cut away any loose "hairs" of melted 

plastic.

5

Using tweezers, hold the conductor in 

place and solder to pole. Keep in mind 

you can heat this bottom pole from the 

underside as well.

4

Strip, twist, tin, and trim the first 

conductor. Start with the bottom-most 

soldering pole. You will likely want to cut 

this one relatively short to keep things 

tidy. (Longer than shown here is fine.)

6

Inspect your work. This conductor was 

worked a bit too much and lost some of 

its insulation, but should still function 

just fine. Watch out for exposed wire 

like this making contact with other 

exposed wires.

2

Tin each section of the pole. You will 

likely melt some of the black insulation 

plastic, but don't worry. Depending 

on your soldering iron, the pole-style 

connectors may require a higher heat 

setting.

The poles are a mirror 
image of the plug. The 
bottom-most pole 
connects to the tip.

Zap Cables Instructional Series 

DIY TRRS Cable Kit Guide

Summary of Contents for DIY TRRS

Page 1: ...DIYTRRS Cable Kit Guide 1 0 Zap Cables Instructional Series ...

Page 2: ...sible 1 Trim position your cord to expose an inch or so of cable More is okay you can cut it shorter later 3 Retain as much of the outer braided shielding layer as possible If you end up stripping most of it away cut the stripped section off and try again 5 Trim away one of the insulated conductors only three conductors are needed 4 Fold the shielding back and trim away the mylar foil 6 Inspect yo...

Page 3: ...wn the cable and out of the way 11 Using a pliers or wire stripper crimp the clamps down as securely as possible Make sure the clamp is gripping both cable and cord sleeving Avoid crimping in only one spot Crimp rotate a little crimp again You want the clamps to hug the cable as much as possible 9 Make sure the shielding is folded back and gather twist it together on one side of the cable 12 Inspe...

Page 4: ...ed off later Just make sure to leave a decent amount of insulated conductor in tact Don t strip it down too far 2 Twist each conductor into a tight braid and tin each one for easier soldering Do not use excessive amounts of solder just a little bit will do If you have large globs you ve used too much 3 Insert one conductor through the hole of a soldering tab Use tweezers to make this part easier I...

Page 5: ... like a round glob sitting atop the tab make sure you are applying enough heat to the tab itself Many solder joint issues can be fixed by re applying heat 10 Inspect your work Make sure the joints look clean If you used flux use some isopropyl alcohol to clean it up Make sure the conductor insulation is still in tact and there isn t a lot of exposed wire 8 Repeat for all conductors tabs 11 Wrap a ...

Page 6: ...the clamp 3 Slide the heatshrink that you applied earlier back up the cable and position as shown Make sure not to cover the threads 5 Slide the connector barrel that you applied earlier back up the cable and screw it onto the plug 4 Use a heat gun or hair dryer to secure the heatshrink tightly to the cable and soldered tabs conductors 6 All done Nice work Give it one last inspection Make sure the...

Page 7: ... the clamps down as securely as possible Make sure the clamp is gripping the cable and the cord sleeving 5 With a flush cutters trim away the excess shielding Make sure you don t leave sharp points or jagged bits that may pierce through the heatshrink that will cover it 4 Solder the shielding to the tab With a tinned soldering tip apply heat to the conductor tab for a second or two then introduce ...

Page 8: ...to the tab 11 Strip twist tin and solder the last conductor to the top most tab Trim and inspect This one may be a little trickier If the black tab insulation is in the way you can try and slide it up for easier hole access or simply cut a little of it away 12 Slide the heatshrink that you applied earlier back up the cable and position as shown Make sure not to cover the threads Apply heat to secu...

Page 9: ...Using tweezers hold the conductor in place and solder to pole Keep in mind you can heat this bottom pole from the underside as well 4 Strip twist tin and trim the first conductor Start with the bottom most soldering pole You will likely want to cut this one relatively short to keep things tidy Longer than shown here is fine 6 Inspect your work This conductor was worked a bit too much and lost some...

Page 10: ...ering pole prep the wire like before and solder it to the pole from the opposite side than you did the previous one Even if the soldering job gets a little messy this will help prevent shorts 11 Slide the connector barrel that you applied earlier back up the cable and screw it onto the plug 9 Trim off any excess shielding and make sure not to leave sharp ends 12 This connector is all done Give it ...

Page 11: ...srhink scootch the double sleeving back into position as shown here The clamp on the TRRS connector will likely not be big enough to fit nicely around the cable with two layers of sleeving so by only clamping around one layer of sleeving it will have a better hold The Techflex or MDPC X double sleeving layer has enough stretch that the heatshrink and barrel will be enough to hold it in place Zap C...

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