Making the Jumpers

The Next Step micro, SSC servo controller, Tracker sensor, IRPD detector, Dual H-Bridge driver as well as many other electronic devices use 0.025-inch square metal posts for making connections. I've become aware that some users aren't quite sure what to do with these header posts. They usually end up wire-wrapping to make their connections. They also end up unwrapping old connections, and fixing bad connections.

There is a better way, if you're willing to invest in a crimping tool and a supply of connectors, you can make slick, secure jumper wires and harnesses. You can purchase the CK-01 Connector kit and have everything you need to make 25 jumpers, more than enough to complete several small robot projects.

The female crimp pins are designed to fit into small plastic housings to make tidy, detachable wiring harnesses of the sort you would find inside PC's. However we are going to use them in a slightly different fashion. You can crimp these connectors onto 22, 24, or 26-guage stranded hookup wire. Follow these simple instructions to make your connectors.

The crimp pins come attached to a ribbon of metal called a carrier strip. Cut a one pin section from the end of this strip, leaving the pin attached to the piece of metal. This tap makes a nice handle for the tiny pin. Strip 1/4 inch of insulation from the end of a piece of hookup wire. Hold the pin by the tab and load the wire into the crimp pin as shown. See the two sets of ears on the crimp pin? Line up the insulation with the back set and the bare wire with the front set.

Using the very end of the crimping tool, pinch the ears gently inward toward the wire. This ensures that it will fit into the concave crimping die. Next, position the back end of the crimp pin against the smallest tooth with the ears pointing into the die. Line up the ears with the funnel shaped opening of the die, and squeeze the handles of the tool. When you open the crimp tool, you'll see that it has neatly wrapped one set of ears around the insulation, and the other around the bare wire. Pinch the bare-wire part of the crimp with the corners of the tips of the tool as final insurance of good contact. You should cover this connector with a short piece of heat-shrink tubing to cover any bare metal. This will protect against accidental short circuits. One more benefit of header-socket pins; they fit perfectly on 22-gauge solid hookup wire for making temporary connections to breadboards and other circuits.