1/8" mini phone splice shell

thingiverse

I needed to connect a 1/8" stereo mini phone male plug with a 3/16" mini phone female connector using two custom-made cables. In the past, I would have spliced them together, soldered the wires, wrapped electrical tape around it, and secured it with a robust knot as strain relief. This shell neatly separates the three conductors, allows for seamless splicing, and provides reliable strain relief when filled with fast-drying epoxy. The internal design eliminates the need for heat shrink, ensuring neat solder joints. The model's design isn't my finest work, but it gets the job done. The four alignment holes may leave slight openings on the outside surface when printed using most FDM printers. However, a small drop of epoxy in each hole and on the mating pins during potting effectively fills the side breakouts, resulting in a flawless look and function. After soldering, I neatly organize the wiring in the three channels and fill it with epoxy. To keep it securely closed while the epoxy cures, I use a compact spring-loaded clamp.