[sdiy] [semi-ot] making patch cables with thin console cable.

[Michael E Caloroso]

I have built my own audio cables for 40+ years.

I strongly recommend not skimping on cheap plugs for patchbay, console, or
rack wiring.

You want Switchcraft or Neutrik.  Beware of "look-alike" counterfeits.
Accept nothing less than the real thing.

Cheap plugs WILL malfunction, and you do not want the aggravation of
chasing down a faulty connection in a rats' nest of cabling, especially
when a recording is in progress!

I made the mistake of buying "switchcraft-like" economy plugs from a
supplier.  1/3 of the plugs were defective out of the bag because the
solder lug for the tip or ring were shorted to the sleeve when they were
assembled, rendering them useless.  Also when the metal shell worked loose,
it would rest on the sleeve and other lugs, resulting in an intermittent
short causing loss of audio.  Even with the internal plastic insulator
intact.  The metal shells just would not stay in place once fully
assembled.  That was a BITCH to hunt down.  I had to add insulating tape
over the lugs on ALL of the cables I built that used those plugs.

You got best quality cable.  Use best quality plugs.

BTW Switchcraft makes plugs with extra large inserts in the shells for
large diameter cable.

MC

On Sat, Sep 5, 2026 at 1:12 PM Mike Bryant <mbryant at futurehorizons.com>
wrote:

>
>
>    - I suspect the recommendation will be heat shrink tubing + neutrik
>    jacks
>
>
> If you are using the best cable, why would you not use the best jacks ? 🙂
> ------------------------------
> *From:* Synth-diy <synth-diy-bounces at synth-diy.org> on behalf of Jimmy
> Moore via Synth-diy <synth-diy at synth-diy.org>
> *Sent:* 05 September 2026 17:44
> *To:* synth-diy mailing list <synth-diy at synth-diy.org>
> *Subject:* [sdiy] [semi-ot] making patch cables with thin console cable.
>
> I got a great deal on a spool of mogami w2944, so time to revive the
> patchbay project.   This is console wire, so has a very thin OD of about
> 2.54mm:
>
> https://mogamicable.com/category/bulk/console/#gsc.tab=0
>
> I foresee this causing some challenges with audio jacks that are designed
> around much beefier wire.
>
> I'm curious if anyone had suggestions for preferred (1/4") connectors for
> this kind of thing.  I have a samson S-patch plus, so no TT or bantam jacks
> for me just yet.
>
> I suspect the recommendation will be heat shrink tubing + neutrik jacks.
> I would love to hear what you think.
>
> jimmy
>
> PS: if anyone has some spare jacks or heat shrink you would be interested
> to sell, let me know!
>
>
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