// CAT PLUG, made for #18(to #22?) with SHEET METAL PINS (.025" Nickel-brass or copper metal ) //Craig Carmichael 2012/10/12 //Flat pins are easy to make from sheet metal. This plug is designed for homemade sheet metal pins. The following "1000 words" of instructions pretty much substitute for a simple picture with dimsensions shown: //Caution: Pins fatter than .025" (.8mm), or bent pins, or pins that insert too far, will bend the tines in the socket, and other plugs will then be a loose fit. //MAKING the PINS FROM SHEET METAL //1. The pins are cut as rectangles, about 5mm wide (3/16") and about 25mm long (1"). I had #18 nickel-brass (AKA nickel-silver AKA german silver AKA Cu:Zn:Ni alloy ~65%:17%:18%). It's okay but a tight fit, so maybe #20 would be optimum. //2. The edges and (at least) one end are smoothed, the end preferably being tapered a bit, with a file. //3. The tapered end is inserted into a vise about 12mm, and it's bent 90 degrees. //4. Turn it over in the vise with about 3mm before the bend now on top. With a blade screwdriver, bend it up. The "L" becomes a "---__". //5. Reduce the width of the end to go inside the plug body by a mm on each side, by crimping it over into an inwards facing "U", or file/cut it thinner. The shoulders ensure the pin doesn't slide out the back when the pulg is inserted inot a socket. //6. You probably won't get a good crimp connection, so solder the wires on securely, Clip off any loose strands. //Moving right along to the 3D printed plug(s)... for(n=[0:1]) { for(m=[0:1]) { translate([n*52,m*25,0]) { difference() { //main body, ONE half - widest point translate([-2,0,0]) { cube([21,22,4], center=false); } //Hand grips for pulling plug out translate([-3,-.5,-.5]) { cube([3,18.5,7]); } translate ([-3,18,-.5]) { cylinder(h=7,r=3); } translate([17,-.5,-.5]) { cube([3,18.5,7]); } translate ([20,18,-.5]) { cylinder(h=7,r=3); } //blade slots translate([2,-.5,.9]) { cube([1.2,6,6.2]); } translate([9.25,-.5,3.3]) { cube([6,6,1.4]); } //Bend Areas translate([2,3,.5]) { cube([4.5,2.5,6]); } translate([5,5.4,.5]) { cube([1.5,2.6,6]); } translate([9.25,3,.6]) { cube([6,2.5,5]); } translate([9.25,5.4,.6]) { cube([6,2.6,5]); } //Wiring spaces translate([2,7.9,1]) { cube([4.25,11,6]); } translate([9.35,7.9,.6]) { cube([6,11,4.5]); } //Wire exits translate([4.25,17.5,4]) { rotate(a=[-90,0,0]) { cylinder(h=6,r=2); } } translate([12.4,17.5,4]) { rotate(a=[-90,0,0]) { cylinder(h=6,r=2); }} //Alignment slot // translate([3.5,1,1]) { cube([5.2,2.2,5]); } //bolt hole translate([7.75,12,-.5]) { cylinder(h=6,r=.9); } //Outer Minus sign translate([16.5,4,1]){ cube([1,3,1]); } //Inner Minus sign translate([10.25,1,3]){ cube([4,1,1]); } // translate([11.75,0,3]){ cube([1,4,1]); } } translate([-9,0,0]) { mirror([ 1, 0,0 ]) { difference() { //main body, ONE half - widest point translate([-2,0,0]) { cube([21,22,4], center=false); } //Hand grips for pulling plug out translate([-3,-.5,-.5]) { cube([3,18.5,7]); } translate ([-3,18,-.5]) { cylinder(h=7,r=3); } translate([17,-.5,-.5]) { cube([3,18.5,7]); } translate ([20,18,-.5]) { cylinder(h=7,r=3); } //blade slots translate([2,-.5,.5]) { cube([1.2,4.5,6]); } translate([9.35,-.5,3.4]) { cube([6,6,1.2]); } //Bend Areas translate([2,3,.5]) { cube([4.5,2.5,6]); } translate([5,5.4,.5]) { cube([1.5,2.6,6]); } translate([9.25,3,3.4]) { cube([6,2.5,5]); } // translate([9.35,4,3.4]) { cube([6,4,4.5]); } //Wiring spaces translate([2,7.9,1]) { cube([4.25,11,6]); } translate([9.35,7.5,1.9]) { cube([6,11,4.5]); } //Wire exits translate([4.25,17.5,4]) { rotate(a=[-90,0,0]) { cylinder(h=6,r=2); } } translate([12.4,17.5,4]) { rotate(a=[-90,0,0]) { cylinder(h=6,r=2); } } //bolt hole translate([7.75,12,-.5]) { cylinder(h=6,r=1.3); } //Outer Plus sign translate([-.5,4,1.5]){ cube([1,4,1]); } translate([-.5,5.5,0]){ cube([1,1,3]); } //Inner Minus sign translate([10.25,2.5,3]){ cube([4,1,1]); } // translate([11.75,1,3]){ cube([1,4,1]); } } //Alignment pillar // translate([3.5,1.1,3]) { cube([5,2,1.8]); } //Bend Area Hump translate([9.35,5.4,3.9]) { cube([5.8,2.6,2.3]); } } } //posn,m,n }}}