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  1. #1
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    Micro cable gland anyone?

    Hi all

    Working on a small helmet light and am looking for a suitably small cable gland to provide weatherproofing and strain relief. So far the smallest I can find has an M12 threaded body, which means the retaining nut a is 19mm dia. (16mm across flats, 19mm corner to corner). As well as being ugly, it takes a lot of space for just a 3-4mm cable. Anyone know of a more compact solution?

    Cheers

    Jez

  2. #2
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    Maplins sell a nice small one but instead of a nut you can put a cable tie around the wire on the inside of the light and fill the gland with silicone before you push the wire through.
    Attached Thumbnails Attached Thumbnails Micro cable gland anyone?-dsc02305.jpg  


  3. #3
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    I just get old cell phone chargers. they usually have molded rubber on one or both ends. Then I simply drill the hole in my housing smaller than the end of the rubber strain relief and larger than the cable. Just feed it on through and epoxy it into place. the price is right.

  4. #4
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    I have one made for my new microlight I'm building. It threads into the light body and seals by compressing an o-ring around the cable and against the light body. It has an M8 thread, an 8mm hex to tighten it, and fits a 4.3mm cable. I'll get some pics of it put up when I start a thread covering the new build

  5. #5
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    This is as small as they come..that i can find..
    M8 thread, fits cable 3.5-5.5mm
    http://uk.farnell.com/jsp/displayPro...-2072-00001000

  6. #6
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    Thanks guys

    Yettibetty, that looks really neat, I've tried Maplins but didn't see anything like you've used. There's a store near where I work so I'll have another look.

    Bikerjay, interesting idea and for a one-off would work a treat. However I have a short production run in mind to spread the machining costs a bit so an off-the-shelf solution would be better in this case.

    Vancbiker, I await your next build with anticipation. Will be interested to see your solution, although as my in-house manufacturing capability comprises a dremel, jigsaw, drill and file, I probably can't replicate it!

    Goldigger, that's pretty much what I was looking for. Not keen on the chrome finish but its a much better size.

    Thanks again

    Jez

  7. #7
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    Jezv
    I have a rather large bag of these I got a couple of years ago you are welcome to a few for the postage cost .

    I use some plumbers solvent adhesive for pvc pipes to weld them to the cable

  8. #8
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    You're a gent Troutie, just the job

    Reckon you could spare, say, 10? Happy to pay for them. Can you remember what they are called or where they're from? Just in case I, or anyone else reading this, ever need more.

    I'll PM you for more info.

    Cheers

    Jez

  9. #9
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    JezV,
    similar to Troutie's here

    I use these ones, slightly larger but also cheaper. I push the cable in too far then just apply a little silicone onto the cable and into the hole on the inside edge then pull the cable back through to the right length. This seals around the cable and also prevents it from pulling out.

    I'll try the plumbers solvent next, good idea Chris

  10. #10
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    Quote Originally Posted by emu26
    JezV,
    similar to Troutie's here

    I use these ones, slightly larger but also cheaper. I push the cable in too far then just apply a little silicone onto the cable and into the hole on the inside edge then pull the cable back through to the right length. This seals around the cable and also prevents it from pulling out.

    I'll try the plumbers solvent next, good idea Chris
    Thanks Emu

    The Troutie-style ones are 2.70 each in the UK. Ouch. Chris, you might want to hang on to those!

    The cheaper ones are 1.29 for a bag of 50. Go figure! Shame they are for 6.3mm cable but the idea gives me a new avenue to pursue. If I can't find anything smaller I guess a cable tie and silly cone is better than nowt.

  11. #11
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    Quote Originally Posted by JezV
    Thanks Emu

    The Troutie-style ones are 2.70 each in the UK. Ouch. Chris, you might want to hang on to those!

    The cheaper ones are 1.29 for a bag of 50. Go figure! Shame they are for 6.3mm cable but the idea gives me a new avenue to pursue. If I can't find anything smaller I guess a cable tie and silly cone is better than nowt.
    The troutie style ones come in a bag of ten, so if thats 2.97 for a bag of ten, bargin..
    website quotes Price Each (In a Pack of 10)
    http://uk.rs-online.com/web/search/s...hTerm=229-3995

  12. #12
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    Quote Originally Posted by Goldigger
    The troutie style ones come in a bag of ten, so if thats 2.97 for a bag of ten, bargin..
    website quotes Price Each (In a Pack of 10)
    http://uk.rs-online.com/web/search/s...hTerm=229-3995


    No its not its price each in a pack of ten so 2.97 each or 29.70 for 10 .
    not bargain

    I paid 0.25 p each 2 years agos iirc

  13. #13
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    Quote Originally Posted by troutie-mtb
    No its not its price each in a pack of ten so 2.97 each or 29.70 for 10 .
    not bargain

    I paid 0.25 p each 2 years agos iirc
    How does that work? Rip off!
    All i can say is cheers for the 3 you sent me Chris
    I bought a pack of heavy duty IP68 metal glands for less..

  14. #14
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    If you want the strain reliefs get one of these for 12.59
    http://uk.rs-online.com/web/search/s...c=av_uk#header

    Kit Contents
    Type.....................Qty....Cable Hole (mm)....Panel Hole (mm)..Panel Thickness
    Edge Protection....20.... .....4................................6.4......... ...................1.6
    Edge Protection....15..........8....................... .........9.5............................1.5
    Edge Protection....15..........10...................... .........12............................2
    Type..............Qty..Cable Hole (mm)....Outside (mm)....Length (mm)
    Strain Relief....20....3.5 - 4.......................5.5 - 6..................23
    Strain Relief....15....5.5 - 6.......................7 - 9.....................35
    Strain Relief....15....6.5 - 7.5....................7.8 - 8.8................30

    You get 20 of the troutie syle strain reliefs for 12.59 plus 30 of the other 2 sizes, and a load of other stuff you may use elsewhere..

  15. #15
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    Just found these:



    Much more reasonable at 2.74 for a bag of 50. They're also smaller than the RS ones and better for small lights.

    http://uk.farnell.com/pro-power/1551...in_merch=true&

  16. #16
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    Quote Originally Posted by JezV
    Just found these:



    Much more reasonable at 2.74 for a bag of 50. They're also smaller than the RS ones and better for small lights.

    http://uk.farnell.com/pro-power/1551...in_merch=true&
    Even cheaper at 10p each.. assuming you dont want 50..
    Troutie style..
    Fixing Hole Diameter:5.5mm
    Cable Diameter Max:4mm
    Cable Diameter Min:3.5mm

    http://uk.farnell.com/hellermann-tyt...5mm/dp/1827046

  17. #17
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    You guys are hot today!

  18. #18
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    Got to spend 20 or more at Farnell though. Stupid postage rules!

  19. #19
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    Quote Originally Posted by JezV
    You guys are hot today!
    You should see me in a skirt

  20. #20
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    Quote Originally Posted by piesoup
    Got to spend 20 or more at Farnell though. Stupid postage rules!
    I was trying to find that, i knew there was some minimum spend or rip off postage costs..

  21. #21
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    Try conrad
    http://www1.conrad-uk.com/scripts/wg...ies=1&cookie_n[1]=uk_insert&cookie_v[1]=8V&cookie_d[1]=&cookie_p[1]=%2f&cookie_e[1]=Thu%2c+06-Jan-2011+16%3a26%3a58+GMT&scrwidth=1280

    4.95 delivery

  22. #22
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    I was gonna try a few of these...................

    http://www.batteryspace.com/componen...thlocknut.aspx

    since I am building up an order anyways with these guys.
    $2.99 a pop is pretty steep, and I bet if I search around I can find em alot cheaper.......but time is money.
    Look, whatever happens, don't fight the mountain.

  23. #23
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    Quote Originally Posted by savagemann
    I was gonna try a few of these...................

    http://www.batteryspace.com/componen...thlocknut.aspx

    since I am building up an order anyways with these guys.
    $2.99 a pop is pretty steep, and I bet if I search around I can find em alot cheaper.......but time is money.
    Same thing - $.60ea

    http://www.alliedelec.com/search/pro...5309#tab=Specs


    Steps for Shopping:

    Google - Search Item - PG Glands for example
    Shopping Tab - Relevance Low to High filter
    Done =]

  24. #24
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    Quote Originally Posted by JezV
    Hi all

    Working on a small helmet light and am looking for a suitably small cable gland to provide weatherproofing and strain relief. So far the smallest I can find has an M12 threaded body, which means the retaining nut a is 19mm dia. (16mm across flats, 19mm corner to corner). As well as being ugly, it takes a lot of space for just a 3-4mm cable. Anyone know of a more compact solution?

    Cheers

    Jez
    If you want a cable gland then there is this mini m6 if you can manage 3mm cable.

    http://www.newark.com/jsp/search/pro...FC-GB100000001

  25. #25
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    Good stuff.
    I just need to figure out exactly what size wire and housing I'll be using.
    Thanx!!!
    Look, whatever happens, don't fight the mountain.

  26. #26
    A waste of time it is is
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    Quote Originally Posted by Goldigger
    You should see me in a skirt
    are you bending over a creek with a gold pan in hand, jiggling about?

  27. #27
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    Quote Originally Posted by kan3
    Same thing - $.60ea

    http://www.alliedelec.com/search/pro...5309#tab=Specs


    Steps for Shopping:

    Google - Search Item - PG Glands for example
    Shopping Tab - Relevance Low to High filter
    Done =]
    That's the missing link, thanks kan3. If you know what things are called it makes finding them a bit easier. The smallest glands seem to be PG7 thread, whatever that means, for cables 2-5mm dia. Plenty of places supply them if you know what you're looking for. I'm still planning to follow Troutie's suggestion with the pvc insert thingy bonded to the cable but good to have a Plan B.

  28. #28
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    Was working on my cad drawing and didn't realize the pg7 used a non standard thread. This gland is the same size as the pg7 version but uses a standard M12x1.5 thread if you wanted to thread it into the housing instead of using their nut.

    http://www.alliedelec.com/search/pro...px?SKU=5000263

  29. #29
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    Quote Originally Posted by kan3
    Was working on my cad drawing and didn't realize the pg7 used a non standard thread. This gland is the same size as the pg7 version but uses a standard M12x1.5 thread if you wanted to thread it into the housing instead of using their nut.

    http://www.alliedelec.com/search/pro...px?SKU=5000263
    Hmm. That's getting quite a bit bigger again

  30. #30
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    It has the same physical size as the pg7

  31. #31
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    The PG7 is 15mm diameter and 32mm long..datasheet drawing http://www.alliedelec.com/Images/Pro...P/500-5380.PDF
    The M6 cable gland is 9mm x 19.7mmhttp://www.farnell.com/cad/320643.pdf
    The M8 cable gland is 11mm x 20.5 datasheet drawing same as above

    M6 is the way to go if you dont mind the price.. 5mm of thread and roughly 15mm will be visible..

  32. #32
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    If you don't mind the connector outside the light than the difference is only 3mm inside/threading. The pg7/m12 coming in at 8mm. You're also stuck with a 3mm cable on the m6 vs the m8.

  33. #33
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    Quote Originally Posted by JezV
    Vancbiker, I await your next build with anticipation. Will be interested to see your solution, although as my in-house manufacturing capability comprises a dremel, jigsaw, drill and file, I probably can't replicate it!
    Here is the solution I am putting together. The gland screws in to a tapped hole in my housing. The translucent ring between the o-ring and gland is a polycarbonate spit ring. it has a taper on the gland side that matches with a taper in the gland. That causes it to squeeze the cable jacket for strain relief. The o-ring is compressed between the cable, split ring and housing to provide a waterproof seal.
    Last edited by Vancbiker; 06-30-2011 at 09:06 AM.

  34. #34
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    Whats the size on them Vanc? thread and diameter?

  35. #35
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    Thread and hex are 8mm. Cable is 4.3mm

  36. #36
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    Quote Originally Posted by Vancbiker
    Thread and hex are 8mm. Cable is 4.3mm
    mmm interesting.. id like to see some pics of it assembled..
    I'm popping to RS tomorrow, to get some momentary switchs, will see if they have any of the M6/8 cable glands..

  37. #37
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    Quote Originally Posted by Vancbiker
    Here is the solution I am putting together. The gland screws in to a tapped hole in my housing. The translucent ring between the o-ring and gland is a polycarbonate spit ring. it has a taper on the gland side that matches with a taper in the gland. That causes it to squeeze the cable jacket for strain relief. The o-ring is compressed between the cable, split ring and housing to provide a waterproof seal.
    See reply 27 in the following thread for how this looks when assembled.

    36-21.5-33

  38. #38
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    Found these M6 cable glands on ebay..
    http://cgi.ebay.co.uk/Cable-Gland-Sm...item35af070097

  39. #39
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    Quote Originally Posted by Goldigger
    Found these M6 cable glands on ebay..
    http://cgi.ebay.co.uk/Cable-Gland-Sm...item35af070097
    Looks a good solution. What cable would you use with these? 3.5mm is pretty slender

  40. #40
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    Quote Originally Posted by JezV
    Looks a good solution. What cable would you use with these? 3.5mm is pretty slender
    Id say 3.5mm max

    I know where your coming from, I need to find some 3 core around 4-5mm that will handle 1-2amps

  41. #41
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    22awg should handle that

    also 3.5mm should fit 22/3 but don't know if you could do 4

  42. #42
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    ok i found 3 core 22awg 4.3mm diameter
    http://www.rapidonline.com/Cables-Co...ource=googleps

  43. #43
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    Quote Originally Posted by Goldigger
    ok i found 3 core 22awg 4.3mm diameter
    http://www.rapidonline.com/Cables-Co...ource=googleps
    Hmm, that won't fit a M6 gland with max 3.5mm cable though. As a matter of interest why do you use 3-core?

  44. #44
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    Quote Originally Posted by JezV
    Hmm, that won't fit a M6 gland with max 3.5mm cable though. As a matter of interest why do you use 3-core?
    Yes i know sorry, i was showing what i had found for my own needs..very selfish of me
    I plan to use a 3 core on the L332MC board so i can have the two switches housed in a small piece of delrin next to each other.. it keeps the wiring all inline and tidy.

    instead of like this


    Have you got any old chargers that you dont use? or even USB cables? I have a round USB cable that is used to charge my phone 5v @ 1amp its 3.5mm thick

    from what i can gather the signal pair are 28awg and the power pair can range from 20-24 awg..
    make sure to use the power pair..
    20 awg - 1.5amps
    22 awg - 0.92amps

    Belkin do a 20/28 usb cable..not sure how thick they are..
    Last edited by Goldigger; 01-14-2011 at 06:16 PM.

  45. #45
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    Quote Originally Posted by Goldigger
    ok i found 3 core 22awg 4.3mm diameter
    http://www.rapidonline.com/Cables-Co...ource=googleps
    That cable has pvc insulation and jacket. That will make it kind of stiff compared to cable with silicone or polyurethane insulation and jacket

  46. #46
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    I'm going to try this

    http://pt.farnell.com/jsp/search/pro...sp?SKU=3855715

    for my next light. 3,5 very flexible. There are several colors
    Hope it will work ok.

  47. #47
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    Quote Originally Posted by Goldigger
    Yes i know sorry, i was showing what i had found for my own needs..very selfish of me
    I plan to use a 3 core on the L332MC board so i can have the two switches housed in a small piece of delrin next to each other.. it keeps the wiring all inline and tidy.
    No problem, I was just being nosey!

    I wondered about this http://www.rapidonline.com/sku.aspx?...catref=02-0260.

    It's 24 AWG 3.35mm dia. and a reasonable price, although postage and VAT bump it up. I think voltage drop is the biggest concern with thinner wire but should be ok for 2 x XPG at 1A from an 11.1v Li ion battery. Probably not up to a quad XML at 3A though.

  48. #48
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    Incidentally, while discussing cables, can anyone tell me the thickness of the wire on the DX Trailtech extension leads? I've a few on the way to try but have no idea whether they will fit my housing

  49. #49
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    I have ordered a coupple of the 3.5mm cable glands that Goldigger found.
    They should be here in a few days, I'll report back when they arrive as to how usefull they are.
    Last edited by yetibetty; 01-15-2011 at 09:25 AM.

  50. #50
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    Quote Originally Posted by yetibetty
    I have ordered a cupple of the 3.5mm cable glands that Goldigger found.
    They should be here in a few days, I'll report back when they arrive as to how usefull they are.
    Cool..

    Is that a new light in your avatar??

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