Topic: How are the molded rubber connectors made?

[bluestang65]

If a guy wants to make them, how would that be done?  I know most everything is available as a reproduction, but I'm doing something outside the norm.  I've seen every type of terminal available from places like NAPA or a few online vendors, but I don't see anything on the standard old rubber molded Ford plugs.  Seems to be identical to the main disconnect on the 4 flat trailer plugs.  Anyone know how they're made?

[bryancobb]

1) Tool & Die Maker hand-carves a 2 piece female mold
2) Resin or rubber is decided on with the desired characteristics
3) Resin in liquid state is injected under pressure, into the mold
4) After curing, the plug, with wires/pins encased in hardened resin, is removed from mold.

[bluestang65]

Where would one get the terminals themselves?

[midlife]

1) Tool & Die Maker hand-carves a 2 piece female mold
2) Resin or rubber is decided on with the desired characteristics
3) Resin in liquid state is injected under pressure, into the mold
4) After curing, the plug, with wires/pins encased in hardened resin, is removed from mold.

A jig is needed to keep the wires and pins centered and/or aligned within the mold itself.  I've inquired about the machines that do this, and they are fairly large...typically blasting cabinet sized.  Used machines run about $10k.

Given the price and the fact that striped colored wires are specialty orders (think $500 minimum purchase), I decided to continue harvesting used harnesses for plugs.  Several vendors sell a variety of 1 to 8 pin molded connectors; I like http://www.delcity.com or waytek wiring.

[bryancobb]

Where would one get the terminals themselves?

Probably mouser.com or similar.