Ham Radio and 3D printing - A shell for Anderson Power Poles and small power cables.

[@davidwilcox9110]

I forwarded this to a ham radio friend, John, KE8VNA, to explore making some of these for his own use. He is stuck down the 3D printing rabbit hole and having the time of his life. He just printed a fan for my garage compressor when there was no other option after my fan broke. What a guy!

[@gilbreathca]

You could model in a hole on each half-shell that aligns with that roll pin hole in the PowerPole assembly. I've often used weed-eater line sharpened to a point (not sure what diameter) and pushed/pulled it through the hole to lock it in place longitudinally. Once the line is inserted, simply trim with a pocket knife, razor blade or flush-cut wire cutters. This will lock the PowerPole and the shells together with a non-conductive "pin".

[@inspector1794]

Great solution to the lack of strain relief of the Power Pole connector. As others have suggested, add a pin to the center hole. Maybe use flat head screws too. No room for a knot on the cable but in the past I've glued a washer on the cable to help keep it from pulling out. Nicely done, thanks for sharing.

[@DonDegidio]

Hi Kevin, How about a small hole positioned where the pin would be used to secure the power poles. You should now be able to use a 2-56 screw to secure the power poles in the shell and possibly do without the 6-32 screws. Stay safe. 73 WJ3U

[@JennyEverywhere]

Nice! I don't use power poles for my QRP rigs, I use Power Delivery, so I can use consumer grade USB-C power banks and chargers. Works great. I used that system at Field Day.

[@notreallydaedalus]

You don't get any RFI from the switching power supplies?

[@dennisjoiner3717]

I was thinking along the lines of "DHL's" comment. Troy's screw idea ought to be stonger still. I love those 3D Printers and TinkerCAD! It's just so cool what one can make with it.

[@razzwilmz7970]

That's worth getting up at 3:30AM in the morning for.

[@markanderson8066]

Reminds me of the clam wheels used with DB9 and DB25 connectors! Glad you're having fun! Happy New Year de WB2SMK

[@notreallydaedalus]

I like to squirt a little dab of silicone adhesive in situations like that. I've also used a little segment of PLA filament, heat-flattening the ends like a rivet, through the gap in the middle.

[@Mottersmotters]

Great video Kevin. Not sure if you can, could you bring the stl of the case into tinker and model a attachment for the case to house it all. No wire then just power pole socket. As for the plug instead of doing it 50/50 make it deep to enclose the plugs and cable then a couple of mm lid for. Is for the cable if it didn't grip make room I. The case for a small cable tie to stop pull out. Plus change the tolerance of the plug cutout. Anyway just ideas no wrong answers here. It's ham radio. Great work 👍🏻 Motters M7TRS 🇬🇧 73 👍🏻

[@astrorad2000]

Great work Kevin! Thanx!

[@Littrell1966]

Use a small roll pin to go through the shells and through the hole in the middle of the power poles.

[@thomasr.jackson2940]

I was just working on the same issue. My solutions were gravitating toward a loop of the thicker wire jacket and some tape, lol. Yours is more elegant, tidier, and probably will work better. I did discover that there are 15amp connector inserts for 20-16 gauge wire (DXEngineering stocks them) but that doesn’t solve the intrinsic mechanical weakness of the wire itself. Thanks!!

[@Ron_pd3ron]

hi Kevin, Thanks for the bright idea to use the power poles for the (TR)usdx . I also have a (TR)usdx, so this also goes in my "wanna have " box for the 3d printer. Ron,pd3ron

[@wb8cxo]

Very nice! Longer roll pin thru the housing and the existing hole in the power pole. Course ya'd hafta source the longer roll pins... Its always something! :)

[@WiltWa]

wb8cxo, you and I are thinking along the same lines. My first thought was an appropriate size screw, probably easier to find than the roll pin! WB7VPI

[@wb8cxo]

@@WiltWa Agreed!

[@heldisanderson]

Hi, great work. You can secure it with center pin.

[@SkyWire88]

Nicely done. I had never seen power poles before.

[@notreallydaedalus]

Careful, they're addictive.

[@CharltonSupporter]

Straightforward design. thanks for sharing this. it has answered a couple of my problems. I will now go and dust off my printer. One thought on the securing of the power poles. Would it be possible to put an additional fixing screw so that it goes through the case where the dowel hole is? Thanks again for sharing. 73s de Rob G4ZRS

[@nr3rful]

Hardened power system has power pole strain relief products

[@davistroy]

I think a 2mm screw will fit in the 2.4mm notch between the two power poles. Put a hole in your case and run a long screw in there. Or try a 2.5mm high x 2.3mm wide nub on the top and bottom parts of your case in that area

[@ri3cjoh]

cool. Good job.

[@W9TSB]

Wonder if you could utilize the through hole that used to lock the power poles together??

[@Inkling777]

For me the learning curve and access to a 3D printer is a factor. Have you tried using J-B Weld epoxy to encapsulate the connectors and attached wires? It is easy to use and solid. My only concern would be whether the "cold-weld steel" variety conducts. If so, I suspect the ClearWeld variety does not.

[@markanderson8066]

This comes apart allowing replacement of broken connectors.

[@dhl5042]

How about a pin thru the center that also goes thru the housing, holding the printed housing right to the PP connectors.

[@coltronex]

Just one word,super!

[@dmcarpman]

nice design

[@joecraft4409]

Great job Kevin. They will have a chinese version up on amazon tomorrow! 😂

[@TheVicar]

Where the inside dimples are in between the connectors, it creates a circular gap. Could you put a smaller screw/bolt through the centre of the shell to push the connectors slightly apart against the inside of the shell, to create more rigidity for the casing, and also preventing the connectors moving inside? Lining them up to match the male to female external interface may need adjustment, or additional spacers each side of the new screw so each side is equally spaced out

[@loughkb]

My concern turned out to be moot. After using it for awhile, the dimples hold the connector very well.

[@darrellbeard2799]

Maybe try some 3M Double Sided tape on the inside of the shell.

[@traveller-nl]

I always used Heat Shrink Tubing to toughen up cables, but this is way cooler. Maybe you can utilize that center hole in the middle of the two the PPoles to secure them better. print a little stub on each half that will fit in that center hole. They don't really have to meet each other if that's too flimsy to print.

[@jimcooksc]

Maybe instead of a plastic nub drill a small hole and insert a metal pin that would engage the small gap in between the connectors.

[@traveller-nl]

Keep in mind that the little pins that come with the PPoles are the size of the PPoles. You need a longer one to use this method.

[@craigpalmer9196]

thanks for the video and the file

[@moosebonsai]

Brilliant!

[@someguy2637]

Kevin, Excellent 3D printer solution to the small wire problem ! I was going to suggest super glue, but you beat me to it. That seams to be the easiest solution, but that makes the arrangement a one and done so it cant be reused. I'd be interested in your final solution. Best Regards, WA3X Paul M.

[@WaltKO4LFE]

Like your videos a lot!! Question on a different subject: You have had the Icom 7300 for a while now and I would like to hear your thoughts on it? Would you buy it again or get a different radio? I am looking about getting one soon.

[@loughkb]

Yes, I'd buy it again. It's a perfect all-around HF radio. I now have the 705, which is like a portable 7300 with VHF and UHF, Dstar, wifi networking, and bluetooth added in. (only 10 watts though)

[@WaltKO4LFE]

@@loughkb Thank you, KO4LFE

[@harmtuntler8555]

Great idea 💡 ty

[@muddyexport5639]

Thanks for another good ‘un! 73

[@thorbjornkarlsson4681]

I like it.

[@kennethblackwell1137]

Is this my excuse to buy a 3D printer? 😃😃😃

[@ri3cjoh]

superglue?

[@guyhornbeck8940]

Kevin: Great solution. Wish i had a 3-D printer. Would you be open to selling me a set? 73 de Guy AE6FE

[@daviddurflinger3104]

I guess if you are sitting out in the desert near Quartzsite, WITH NOTHING BETTER TO DO, this horseshit is awesome 👌

[@w3les]

Kevin another great video .... ps send you a email