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Author: laxap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
step 9: Tune it . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
http://www.instructables.com/id/Repair-a-Broken-Ethernet-Plug/
Author: laxap
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If I inspired you, share it: post photos in a comment, and you'll get a patch.
I am an engineer, wanting to learn to sew, to weld, and to play the guitar... And I *love* the Instructables site and its community!
IMPORTANT NOTES:
- This must be regarded as a temporary "Mac Gyver" solution, for home usage.
- Definitely not for IT staff! (no crimper? asking for one in the budget won't get you fired!)
- Before the tab breaks, consider protecting the plug.
Now the RJ45 plug no longer locks properly, making the connection unreliable. You firmly push the plug into the socket, hurray you're connected again! so you forget
about the plug until the next lost connection some weeks later, wasting a long time to figure out that it's this damn broken plug again. And so on.
Now it's time to act and grab your RJ45 crimp tool. Oh, you don't have one? Or you're reluctant to use it? so read on...
http://www.instructables.com/id/Repair-a-Broken-Ethernet-Plug/
step 2: Needed Stuff
Tools:
Materials:
Image Notes
1. cable tie tool (optional)
2. X-Acto knife
3. cutting pliers
4. two cable ties; for size considerations see next step.
To test, insert the head into the socket as shown in the first picture below. It should snap.
Then gently pull the cable tie. You should feel some resistance.
http://www.instructables.com/id/Repair-a-Broken-Ethernet-Plug/
Image Notes
1. 4.3mm
Image Notes
1. approx 4.5 cm (1.8 inches).
http://www.instructables.com/id/Repair-a-Broken-Ethernet-Plug/
Image Notes
1. the excess part has been removed
Image Notes
1. here
2. here
3. here
http://www.instructables.com/id/Repair-a-Broken-Ethernet-Plug/
step 7: Use the Cable Tie #2
With the second cable tie, tighten the first one.
Image Notes
1. 1: pull firmly
2. 2: twist to cut
Image Notes
1. ok, it won't break; but how is it meant to work?
step 9: Tune it
Tune the position and bends of the cable tie #1, so that it acts as a spring.
http://www.instructables.com/id/Repair-a-Broken-Ethernet-Plug/
Image Notes Image Notes
1. <-- tune position --> 1. when pressed, they should touch here
2. tune angles, to produce a spring effect
Image Notes
1. >click<</td>
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http://www.instructables.com/id/Repair-a-Broken-Ethernet-Plug/
Comments
50 comments Add Comment view all 176 comments
Thanks man.
FYI if you have a plug you really need to be stable and not break, check out Panduit's RJ45 connectors, the tabs are built a little bit differently so they don't
break as fast.
http://www.instructables.com/id/Repair-a-Broken-Ethernet-Plug/
WPee says: Sep 23, 2009. 1:32 PM REPLY
There needs to be a GREAT SHOOT-OUT between Cable-Ties VS DUCT TAPE There should be at least 2 classes in this shoot out; one WITH a
DREMAL Tool ALLOWED and the other class WITHOUT a DREMAL Tool ALLOWED :-) :-)
We need a similar slogan for the NEW SCHOOL 'bailing wire' guys who use high tech 'Zip-Ties' and 'Tie-Wraps'.
Also I would like to include the 'VELCRO' guys too.
http://www.instructables.com/id/Repair-a-Broken-Ethernet-Plug/
erikos kostarikos says: Sep 23, 2010. 9:22 AM REPLY
VERY useful, my father used it too, his cable was broken and he tried to tape it on his laptop but it still fell out.Now he is very thankful to you.=]
http://www.instructables.com/id/Repair-a-Broken-Ethernet-Plug/
rocketguy says: Sep 17, 2009. 9:56 AM REPLY
Nice Hack! This is a great improvised solution, for where that's appropriate.
Furthermore, I'd like to see a tab design that is more like this than the current style, as I've only seen one that doesn't suck, and it's pretty much the same
idea but attached at both ends, sorta like a leaf spring.
Two bits of advice though: as others have noted, crushing the cable is both easy to do and a bad thing. I was thinking 5min epoxy on the jack head, but that
would be harder to do right. Just be careful I guess.
Secondly, the days of building your own cables is really past, *don't* do it! As much as I love DIY, hand crimping doesn't hold a candle to the $20K machine
that does factory made cables, crimp depth and so forth are regulated at the factory, not at the hand crimper. They're generally cheaper store bought than
the time you'd spend messing around with it, and goal #1 is reliability.
A bad hand crimp (and they're virtually impossible to do well) can really take a long time to figure out while troubleshooting. The fault can be both intermittent
and not bidirectionally broken. The worst part is that it's never clear if it's been done right, even if you have the right heads/cable type. I speak from vast
networking experience, 60K+ node network and 16 years on the job. Just not worth it, resist the urge!
However, I would like to note that flat satin is okay for cables shorter than the minimum length of cat5.
To begin with they are about 6 to 8 times more expensive then DIY ones. They only come in predetermined lengths that are generally rarely
suitable for the application unless the application has been specifically engineered for them. Next the failure rate for the "factory made" ones is
one out of one hundred... about the same as a home crimp... why? because the dies wear, insulation doesn't cut right, wires snap, etc... the
reason why the factory ones *Seem* so good is that they are tested before packaging. Even there the tests are quick continuity tests. Only about
one in a hundred are sent to QA to be thoroughly tested.
On the home use side, I actually have to have a stash of several different lengths in order to find one that will match and don't get me started on
longer runs. If you get the proper tools and a tester there is no reason why a DIY crimp can't be every bit as good as a "factory" crimp. Especially
if you make several short practice cables to get the feel for doing it.
Maybe you have the nice deep corporate budget and regimented installation where factory crimped cables turn out to be easier but the average
Instructables user does not have that luxury.
Finally, this is an expedient that is especially useful for field work and for low stress applications where the wiring only gets disturbed
occasionally. I have had the clips snap off the ends of a perfectly good cable several times when trying to reroute the cable and this "fix" is an
excellent idea.
Getting factory made whenever possible is a great idea because you have the option of returning it to the place of purchase if it fails out of the
http://www.instructables.com/id/Repair-a-Broken-Ethernet-Plug/
box. However, DIY can be done every bit as well if not better if taken the time to do carefully and properly.
(Tip: always drill the hole between the baseboard and quarter-round or other shoe molding. It's usually painted, so if you have to pull out
the cable; a little calk/some paint, and you can't tell there was a hole. IOW, drill at an angle into the top of the shoe molding.)
All that said, this is definitely going for what my mom calls "the nth degree" of reliability. Great and even necessary for an enterprise
network, less important for a 3 node home network. So it's a judgment call. I'd spend the extra $15 on jacks and stuff if you make a
living off it and need it to always work. But I'm kinda anal about these things, which is why my mom has phrases like "the nth degree"
in her vocabulary.
http://www.instructables.com/id/Repair-a-Broken-Ethernet-Plug/