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    #16
    Originally posted by wireguru View Post
    d@&m you all who have talked about forgetting the back shell. I have been installing cord caps all month (im at somewhere around 300) and havent missed one backshell. I went back to it after participating in this thread and guess what happens.....
    HAHA! good for you, you just couldnt missing out on the grief huh? :grin:

    ~Matt
    I would rather beg for forgiveness then beg for permission.

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      #17
      It builds Character . Even more fun is when you're soldering them.

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        #18
        Originally posted by zbang View Post
        ... the connectors that fail ... almost always all of the leads are loose. ...
        That is the point I was trying to make. The connections do not seem to stay tight like they should and when then losen enough they fail. I don't think I have ever taken a flexible cord connection apart that has been in use for any length of time where the terminations did not seem loose to me.
        Don, Illinois
        (All code citations are 2017 unless otherwise noted)

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          #19
          Originally posted by zbang View Post
          It builds Character . Even more fun is when you're soldering them.
          Yep, and, over the years, on more AV cables than I care to remember.
          Master Electrician
          Electrical Contractor
          Richmond, VA

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            #20
            Originally posted by don_resqcapt19 View Post
            That is the point I was trying to make. The connections do not seem to stay tight like they should and when then losen enough they fail. I don't think I have ever taken a flexible cord connection apart that has been in use for any length of time where the terminations did not seem loose to me.

            then they were not installed properly (i am speaking to hubbell and leviton connectors here). I just disassembled 80 hubbell 5-15 connectors which had been in service for a period of time ranging from 5-10 years. They were installed on 12/3 SO cord, and were used under heavy load (1000w - 2000w) often for long periods of time. out of the 240 wires in terminals, one was loose and it was melted. All the others were still tight.

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              #21
              Are you making or breaking the connections under load? Even though they rated to be able to safely do it(you don't want it blowing up in your face), they are not designed to last long if you do. Everytime you pull the plug live, the arc eats away at the contact areas and that adds resistance which in turns makes it get hot. Switches have contact surfaces that are designed to last when making and breaking under load. Plugs and connectors do not.

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                #22
                Originally posted by wireguru View Post
                that would make it worse. under pressure from the terminal the solder will cold flow and result in a loose connection. The instructions on a Leviton twistlock (and these are just as good as hubbell now days) say in bold letters "do not tin conductors".
                Good point. I forgot about the cold-flow issue.

                Originally posted by don_resqcapt19 View Post
                That is the point I was trying to make. The connections do not seem to stay tight like they should and when then losen enough they fail. I don't think I have ever taken a flexible cord connection apart that has been in use for any length of time where the terminations did not seem loose to me.
                When making up ANY pressure plate style connection, I tighten them up, wait a moment, tighten them again finally check them one more time. They ALWAYS need more tightening when I check them the first time and very rarely the second. Seems as though the wire compresses slowly or something.

                Originally posted by wireguru View Post
                then they were not installed properly (i am speaking to hubbell and leviton connectors here). I just disassembled 80 hubbell 5-15 connectors which had been in service for a period of time ranging from 5-10 years. They were installed on 12/3 SO cord, and were used under heavy load (1000w - 2000w) often for long periods of time. out of the 240 wires in terminals, one was loose and it was melted. All the others were still tight.
                Willing to bet the loose one was probably never tightened enough in the first place.

                Originally posted by Cmdr_Suds View Post
                Are you making or breaking the connections under load? Even though they rated to be able to safely do it(you don't want it blowing up in your face), they are not designed to last long if you do. Everytime you pull the plug live, the arc eats away at the contact areas and that adds resistance which in turns makes it get hot. Switches have contact surfaces that are designed to last when making and breaking under load. Plugs and connectors do not.
                Good point. Just take a look at ANY plug which has interrupted load and see how badly scarred it is!
                [COLOR="Purple"]Never fear, Slick is here..... [/COLOR]

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