PJ-068 Paperclip Socket

thingiverse

This is a microphone jack for a general aviation headset designed to work seamlessly with a jumbo paperclip (1mm diameter). The socket's layout features only common and mic connections, making it incredibly user-friendly. Although I omitted the PTT connector location, adding it would be a straightforward process for anyone familiar with modifying files. This design was specifically created to connect a headset to an FT-897D radio. The circuit used here has been thoroughly tested and proven effective: http://www.dj2um.com/2012/04/15/aviation-headset-interface-ft897/. To assemble this device, you'll need the following materials: strong glue (such as epoxy), a single jumbo paperclip, 2 wires, a wire cutter capable of cutting through the paperclip, a soldering iron, solder, and small pliers. A drill bit will likely be necessary unless your printer produces perfectly sized holes. Post-Printing Instructions: Step 1: Drill out the center hole for the connector using a .206" or slightly larger drill bit. I used a number 4 drill bit, size .209", which worked flawlessly. If your print results in a perfectly sized hole from the start, this step can be skipped. Step 2: Cut an inch or two of straight metal from the paperclip and insert it through the hole on the circumference of the socket featuring the internal groove, not the external one. Push the male PJ-068 plug through the hole until the paperclip is obstructing the large center hole where the male connector passes through. Trim the excess as desired, ensuring enough remains for a wire to be soldered onto it. Step 3: Cut another inch or two of straight paperclip and bend it according to the picture. This process may require some trial and error; aim for it to touch the mic connector of the male plug, leaving room for final adjustments after gluing. Step 4: Solder wires to the paperclip before gluing. For better results, use a small clamp or soldering heatsink to draw heat away from the plastic and prevent it from melting. Step 5: Glue the common paperclip in place (the one resting in the internal groove). Ensure the glue fills the small hole the paperclip passes through but avoids the interior of the large center hole and the groove. This will allow you to bend the paperclip slightly inward for a solid contact with the male plug after the glue is set. Step 6: Apply additional glue around the mic contact paperclip connector, then place it in position followed by the external ring (with more glue) for reinforcement. Step 7: After the glue has reached full strength (usually within 24 hours for epoxy), bend the paperclip that should contact the mic portion of the male connector into its correct position. Slightly bend the paperclip that should contact the common portion of the male connector inward toward the center of the large hole to ensure a good connection.