One of my favorite plugs to use for the small stuff are Deans Micro plugs. They compact and easy to solder. Because the package gives no real direction on polarity, plugs coming from the source are wired so that the high is the female, and the return is the male. Of course, they are opposite coming from the load, the high is the male and return is the female. This makes anything I use with them universal, allowing me to grab LEDs off of one rig and put them on the other with no rewiring.
The biggest thing I use these plugs for are LEDs. But, plugging a number of different LED strings in can make wire management a bit of a nightmare. Taking a que from the distribution/PS block that comes on the TRX4/6s, I set out to design a block that uses the Micro Deans.
Why not use the Traxxas block and save some time? It only poops out 3VDC, and the LEDs I use need at least 4VDC to turn on.
Here is the finished product...
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Scott O, on Flickr
You can see where the CA glue got away from me... Luck my fingers aren't still attached to it...
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Scott O, on Flickr
I designed the block body first, and quickly realized that I would need a jig to hold everything steady for soldering. My first attempt a soldering was laughable because I kept chasing the jig across my workbench; given that this matt is magnetic, I solved the problem with some magnets and CA (again, lucky it still isn't attached to my fingers).
The jig is designed so that the Deans can only go in one way, and so that it is easy to tell where the wires go.
Untitled by
Scott O, on Flickr
Untitled by
Scott O, on Flickr
I used 18ga wire, stripping back about an inch, then tinning the stripped length. More or less this made a bus bar attaching individual connectors together. Certainly not my prettiest soldering job, but as a prototype, not terrible either.
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Scott O, on Flickr
I clipped off the excess and put it into the block. I was/am a little uncomfortable with how much it squeezed the connectors together. I need to go back and add a little room in this area to accommodate the bus bar. As it sits, there is plenty of room between the poles to prevent arcing.
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Scott O, on Flickr
To hedge my bets, I poured some liquid electrical tape in, just to make sure nothing arced. But, the pictures make the leads look like they are almost touching, that is just parallax error, and not really that close.
Untitled by
Scott O, on Flickr
I will wait until I build the next one with the changes before I post it up to Thingiverse, want to do a little testing first. But, once I get the kinks worked out, this would clean up the wiring a bit.