Power Cord made easy
Here is a short how-to on power
cord made from 47Laboratory OTA (Open Technology) cable. Of course,
all of many times repeated warnings apply. If you decide to make it
and use it, you are doing it entirely on your own responsibility. You
wont be able to hold me or anyone else responsible for any eventual
damage to your health, life or your equipment. The one to blame is you.
In the top right corner you can see excess material that we will throw away.
The side that goes to mains outlet is now finished after we've placed these two wrapped ends and screwed them. What I can't tell you is how much force is enough when screwing in the wire... That is something the feel you get with experience. If you screw it too much, you will likely cut off the wire with the screw and if you screw it too little, the wire will fall out...
Having one side completed, we now go to the other, IEC side. The key here is to have everything layed out nicely as here we want to have things done consistenlty, marked string must go on the same side and unmarked one to the other side of every IEC connector.
On this photo you can see that IEC connectors are also not immune from things we won't need. Top line shows excess material that we will throw away.
Here is a trick I use to be sure to have enough "meat" to make a good contact. I bend the bare wire few times...
Once you've screwed in all the contacts, since
we won't be using the screws to fix back the connectors, you may use some
super glue to fix back the housing (alternative is to use electrician
tape but I recommend using super glue, even if it makes a permanent connection).
As you can see, all green marked wires are
installed to the left side and all unmarked ones are on the right side.
We want to have LIVE on the side marked with red marker and Neutral on the other (we don't want ground, that is why we haven't used three wires per IEC but two). We want to have it consistent throughout the setup. With a consistent side assignment of marked vs unmarked wires that is exactly what you achieve - you plug in the mains power connector to the wall outlet, check the polarity on one IEC connector and if you have the live on the side marked red, you will have it on all IEC connectors the same, the good way. If polarity checked shows you have it on the other side, just unplug and rotate the mains power connector for 180 degrees and you will have Live and neutral where they should be... on all IEC connectors. Couldn't be easier to achieve the polarity consistency throughout the setup.
The result of our work you can see on the photography on the top of the page. You can see that I've usd also a few plastic locking strips (dunno how they are called in English). You know, the stuff that is used to keep wires together....
Is it good? Well, I hope you will tell me after you have tried it.
copyright 2012. Konus Audio Systems