Step 0: First will start with the supplies
•Dupont Jumper Wire Cable Male Pin Connector
•Dupont Connector Housing Female 2.54mm 1x1P
•TE Connectivity 2-173983-x (where x=2,3,4,5,6,7,8, or 9)-->Called the TE connector from here on
•24 to 28 AWG wire
•Dupont Crimping tool
•Razor Blade Knife
•Needle Noise Pliers
Note: This documentation describes Open Hardware and is licensed under the CERN OHL v. 1.2.
You may redistribute and modify this documentation under the terms of the CERN OHL v.1.2. (http://ohwr.org/cernohl). This documentation is distributed without any express or implied warranty, including of merchantability, satisfactory quality and fitness for a particular purpose. Please see the CERN OHL v.1.2 for applicable conditions.
Step 1: Remove the contact from the TE connector.
Using a razor blade, cut into the TE connector as shown above. You do not have to use much force. The goal is just to loosen the plastic so that the contact can be removed. As seen below, I stopped cutting right above the contact.
To remove the contact after cutting the plastic, just push on the bottom of the contact up through the connector.
Step 2: Prep the Dupont Connector
Take the Dupont Jumper Wire Cable Male Pin Connector and cut most of the pin off using the wire cutters. The second picture shows how much to cut.
Step 3: Solder the TE Contact to the Dupont connector
Place the TE Contact next to the cut Dupont connector. Use some masking tape to secure them.
Solder the pieces together. Do not use much solder as the Dupont Housing is not much bigger than the TE contact body and the housing will provide a lot of support.
Here is a picture with the correct amount of solder on a final connector next to a contact. Notice that the soldered contact is bent a little bit. I used the needle noise pliers to make the contact not stick out as much:
Below is a picture of the final connector with a bit too much solder on the TE contact top section.
Step 4: Add the wire and housing
Using the Dupont Crimping tool, insert the pin and a wire that has been stripped at one end into the crimping tool.
The Housing will be inserted next...more of a press fit, so some needle noise pliers may need to be used to insert the pin into the housing.
The TE contact pins may need to be bent out slightly after being inserted in the housing.
You are done!
Step 5: Admire your work