[sdiy] 0.100 pin header reliability.

David Ingebretsen dingebre at 3dphysics.net
Fri Nov 12 06:06:21 CET 2010

I'll share some of my limited experiences. Stew makes some good points about
soldering v. crimping. However, in theory, if you use the proper tool for
inserting the wire into the female connector, the wire "cold welds" to the
female pin and forms an airtight, therefore corrosion resistant bond. I've
been using this tool:


with this head:


with these female connectors:


They seem to make a very good mechanical connection and haven't had a
failure in several hundred individual connections.

As to the female to male reliability, I don't pack my stuff very often. I
recently took my two tall racks which contain several modules using this
type of connector in the back of my Tahoe and had no problem. But that is
only one trip.

I using these connectors exclusively with my Synthasystem resurrection which
will be racked into Gator portable cases. I'll know more as time goes on.

If you get the male/female with locking tabs, you will probably have better
luck with regard to vibration. Most commonly used metals in electronics will
oxidize especially if used in a corrosive environment so any connector,
short of an expensive specialized sealed connector, will probably oxidize
over time depending on where it is stored/used.


~~ -----Original Message-----
~~ From: synth-diy-bounces at dropmix.xs4all.nl [mailto:synth-diy-
~~ bounces at dropmix.xs4all.nl] On Behalf Of Stewart Pye
~~ Sent: Thursday, November 11, 2010 9:32 PM
~~ To: sdiy DIY
~~ Subject: Re: [sdiy] 0.100 pin header reliability.
~~ Hi Dave,
~~ FWIW I'm an electronics technician. Here's my experiences...
~~ I've generally only seen the contacts fail if the equipment is in hash
~~ corrosive environments.
~~ However I have seen many failures where the wire was only crimped to the
~~ pin (I'm talking about the female housing now). After time it seems that
~~ the wire oxidises and the connection between the wire and pin becomes
~~ bad. I always solder the wire to the pin and have never had a problem
~~ with any connections I've done.
~~ I find the easiest way to do this is to leave the pins on the strip,
~~ then just bend the sides of the pin in a bit so it will fit into the
~~ shell easily later, tin both the pin and the stripped wire, then solder
~~ them together. Once this is done you can squash the back end of the pin
~~ over the insulation of the wire. The guys I work with prefer to separate
~~ the pins and crimp them using the appropriate tool and then solder them.
~~ Maybe they can do it that way as fast as I do it my way but, but I'm
~~ damn sure I can't!
~~ I would never use the insulation displacement type female connector that
~~ suits these headers as I've seen too many failures.
~~ Cheers,
~~ Stew.
~~ Dave Kendall wrote:
~~ > Hi All.
~~ >
~~ > Do any of you have an opinion on the long-term reliability of 0.100
~~ > connectors like these;
~~ > http://www.rapidonline.com/Cables-Connectors/Connectors-Multipole/PCB-
~~ Interconnect/Straight-pin-header/28953
~~ >
~~ >
~~ > They make assembly much easier and neater (at added cost), but how
~~ > good are they in the long term? I'm not so bothered about the number
~~ > of reliable make/break cycles, just whether they generally hold good
~~ > once installed, and whether vibration from handling or road use causes
~~ > any common problems. I once had an Ensoniq EPS that had known issues
~~ > with a power multipin corroding and causing failures years ago (when
~~ > ensoniq actually *had* a service centre in Putney, London, UK)
~~ >
~~ > Anybody got any real-world advice?
~~ >
~~ > Thanks in advance,
~~ >
~~ > cheers,
~~ > Dave
~~ >
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