How to Assemble a Molex Connectorby Jonra Springs
Molex produces a variety of electronic connectors for consumers, engineering firms and manufacturers. Molex connectors are used in automotive and marine 12-volt systems, computers and accessories, and audio-visual components. The company makes connectors for most common electronic uses as well as the individual parts for each product. The company also manufactures the tools needed to assemble its connectors, such as the Molex crimp tool. Everything you need for making your own Molex connectors is available at any electronics retail store.
Lay out the planned connector assembly with the wires beside the plug and socket. Sockets are slightly larger and the plugs fit inside them. Put a male terminal pin beside every wire going to the plug and a female terminal pin beside each that will attach to the socket. Decide which wire goes into which plug and socket terminal for proper connections.
Use your wire strippers to strip 5/8-inch of insulation off the wires to be attached to Molex connectors. Twist the individual wire strands together between your thumb and forefinger.
Lay the stripped wires into their respective connector terminal pins with the bare wire on the sleeve but not in the tube. The insulation should come past the crimp area by about 1/16-inch. Cut the bare wire as necessary to meet both of these conditions.
Crimp the wires into the conductor crimp area of the connector pins with the appropriate sized v-section of the Molex crimp tool. Molex recommends pinching the crimp around the insulator with a v-shaped section of the jaws as well. Other crimp tools are made with circular notches on the jaws for crimping the insulation area in the shape of the wire.
Push the connector terminal pins into the plug and socket housings. The fins, or locking tangs, will snap once the pins are inserted properly. Plug the homemade Molex electronic connector sections together.