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> Modular Plug Crimping Guide

Introduction

Networking and phone line cables are both available pre-made at a set length. However, sometimes the lengths of the pre-made cables are simply too long or too short. With a few easy to find supplies and tools, you can create your own customized phone or network cables. Crimping your own cables is also cheaper overall than buying a large number of pre-made cables. By following this walkthrough guide, you can create cables with the exact length that you want, and save money in the process.

There are many types of networking or phone line cables that can be made, but the two basic components are modular plugs and twisted pair cables. In this example we will be constructing a simple CAT5 straight through patch cable with RJ-45 modular plugs, which is commonly used for Ethernet connections. There are many other types of cables, though, so be sure to look up the exact ordering of the wires and modular plug type that you will need for these cases (some examples include modular plugs with 4, 6, 8, or 10 pins).

Part List

In order to create a cable, the following parts are needed:

Image	Part	Description
	Modular Plugs	End connectors for the cable that will fit into sockets of devices
	Twisted Pair Cable	Cable with twisted wire pairs enclosed within a layer of insulation

In addition, you will also need the following tools:

Image	Part	Description
	Cable Strippers	Tool to cut the outer layer of insulation on a twisted pair cable, leaving the twisted wire pairs inside the cable still intact
	Wire Cutters	Tool to cut the cable at an appropriate length, as well as trim the inner wires to the appropriate length
	Crimping Tool	Tool to fasten the modular plug on the end of the twisted pair cable

Setup Guide

Step 1: Strip Outer Layer of Cable Insulation. Place the cable in the correct location of the cable stripper, tighten the strippers over the cable, and cut the insulation all around the cable. Discard the excess insulation.

Figure 1: Place cable in correct position in cable stripper.	Figure 2: Cut the insulation all the way around the cable.	Figure 3: Remove and discard excess insulation.

Step 2: Prepare the Wires. Separate the groups of twisted wire pairs, and untwist them. The wires should be placed in an order depending on what type of cable you want to make. Figure 5 shows a diagram with the order (TIA-T568B) of the wires for making CAT5 straight through patch cable. Figure 6 shows how the diagram corresponds to the actual modular plug. It is important to note that the clip of the RJ-45 modular plug should be facing away from you.

Figure 4: Separate the wire pairs and then untwist them.	Figure 5: Verify how the wires should be ordered. The diagram provided is T568B straight-thru. Other possible wiring schemes are T568A and RJ61X.	Figure 6: The ordering of the pins is shown, with clip facing away.

Step 3: Adjust and Trim the Wires. Adjust the untwisted wires so that they are in the order shown in Step 2 (or the order for the type of cable that you are making, if different from the example). Then use the wire cutters to trim the wires so that they are of equal length, and exposed about 1/2 inch from the insulation.

Figure 7: Place the untwisted wires in the correct order.	Figure 8: Evenly trim the wires so that they are exposed about 1/2" from the insulation.

Step 4: Place the Wires in the Modular Plug. Insert the wires into the modular plug, making sure they are inserted as far as they can fit. It is important to verify that the modular plug clip is facing away from you; the order of the wires should also match the picture.

Figure 9: Wires should be inserted into the modular plug in the correct order.	Figure 10: Make sure that the wires are inserted as far as possible, and the clip is facing away from you.

Step 5: Crimp the Modular Plug. Place the modular plug (with the wires still inside) into the crimping tool. It is important that the modular plug corresponds to the slot for the crimping tool. Then, grasp the handle firmly and squeeze it until the modular plug is locked onto the cable.

Figure 11: Insert the modular plug and wires into the crimping tool.	Figure 12: Make sure that the modular plug fits all the way in the crimping tool.	Figure 13: Squeeze handle of crimping tool firmly, until the modular plug locks onto cable.

Step 6: Repeat Process with Other End of Cable. The cable with modular plug attached should be removed from the crimping tool. Next, cut the cable to the desired length, leaving a little bit extra to account for the section that you will be crimping. Then Steps 1 through 5 should be repeated on the other end of the cable in order to create a straight-through patch cable.

Figure 14: Remove the end of the cable with the modular plug from the crimping tool.	Figure 15: Cut the cable a little bit longer than the desired final length of the cable.	Figure 16: Repeat Steps 1 through 5 on the other end of the cable.

Cable Strippers

Image	Part #	Description
	HT-501	Universal stripping tool for round cable

Wire Cutters

Image	Part #	Description
	TOOL-P-28	Bassic wire cutters
	LY-2028C	Wire cutters and stripper for 0.9 to 2.0 mm wires

Crimping Tools

Image	Part #	Description
	TOOL-RJ-12	RJ-12 crimping tool, supports 6P6C modular plugs
	TOOL-RJ-45	RJ-45 crimping tool, supports 8P8C modular plugs
	TOOL-10P10C	RJ-50 crimping tool, supports 10P10C modular plugs
	DL-1008	RJ-45 and RJ-12 crimping tool, supports 6P6C and 8P8C modular plugs
	TOOL-RJ-4512	RJ-45 and, RJ-11, and RJ-12 crimping tool, supports 6P4C, 6P6C, and 8P8C modular plugs
	DL-1068	RJ-45 and, RJ-11, and RJ-12 crimping tool, supports 6P2C, 6P4C, 6P6C, and 8P8C modular plugs

Modular Plugs

Image	Part #	Description
	6P4C-RS-50	6 Pin 4 Connector modular plugs for round cables, in bags of 50
	6P6C-RS-50	6 Pin 6 Connector modular plugs for round cables, in bags of 50
	8P8C-RS-50	8 Pin 8 Connector modular plugs for round cables, in bags of 50

Twisted Pair Cables

Image	Link	Description
	CAT5E Stranded	1000 ft CAT-5E Stranded Cable
	CAT5E Solid	1000 ft CAT-5E Solid Cable
	CAT5E Shielded Solid	1000 ft CAT-5E Shielded Solid Cable
	CAT5E Plenum Solid	1000 ft CAT-5E Plenum Solid Cable
	CAT6 Stranded	1000 ft CAT-6 Stranded Cable
	CAT6 Solid	1000 ft CAT-6 Solid Cable
	CAT6 Shielded Solid	1000 ft CAT-6 Shielded Solid Cable
	CAT6 Plenum Solid	1000 ft CAT-6 Plenum Solid Cable

Cable Information:

CAT5E vs. CAT6 Cable

CAT-5E - supports speeds up to 100 Mbps
CAT-6 - supports speeds up to 1 Gbps

Stranded vs. Solid Wires

Stranded - copper wire conductor is composed of several smaller, interwoven wire strands
Solid - copper wire conductor is composed of one solid copper wire

Unshielded vs. Shielded Cable

Unshielded - cables are not magnetically shielded, and may be subject to interference from outside sources
Shielded - cables are magnetically shielded, and protected from interference from outside sources

Non-Plenum vs. Plenum Cable

Non-Plenum - cables may release toxic gases if they are burned
Plenum - cables are fire resistant and will not release toxic gases if they are burned

Conclusion

Creating networking and phone cables is not difficult, and can greatly improve your cabling setup. In addition to being more cost effective than pre-made cables, the cables that you make can also be fit to the exact length that you need. This guide covered how to make CAT5 straight through patch cable, but the many other types of modular plug cables are created using the same process.

PI Manufacturing carries a large variety of cable supplies, as well as the tools needed to create the cables. Let PI Manufacturing help you with all of your cable needs.