Printed HBP Power Connector

thingiverse

I investigated the issue with the connectors on my Thrustmaster HOTAS Warthog (TOM), which were melting due to being rated for only 75 degrees Celsius when operating temperatures reached 100+ degrees. I designed a solution using two Mill-Max parts, rated for 11.5 amps and capable of operating at 150 degrees Celsius. These parts are compatible with pin #6142-0-00-80-00-00-33-0 and female #0368-0-33-01-13-27-10-0, available for free on Mill-Max's website. To implement this solution, follow these instructions: 1. Order the two Mill-Max pins from Mill-Max's website, which will arrive in a day or two. Also, get some 1/4 inch Heli-tube from your local electronics store. 2. Print two of the power connectors (or create your own improved version) attached to this post. 3. Prepare the TOM board by removing the old power connector with pliers and removing the old pins with a soldering iron, using solder wick for clean removal. Scratch off the solder mask from the vias on the main two power connections to improve conductivity. 4. Trim the rounded tops off the male pins so they lie flat on the PCB. 5. Solder the pins to the HBP PCB using the printed connector and female pins as a guide for proper alignment and leveling. Ensure the male pins are pushed into the female pins until they reach their internal stops before soldering. 6. Solder the wires to the female pins, following the color order: blue, black, red, black (20 gauge), green, white. Place them in their holder. 7. Secure the two printed parts together with two 3mm x 10mm screws. 8. Use Heli-Tube to contain and provide strain relief for the TOM's wiring. This improves the overall appearance and functionality. 9. Plug in the new connector, and your TOM is ready for use again!