How to install a PL259 My Way by

How to install a PL-259 My Way! by Steve, N 1 NXU

Start with a clean cut. • Notice how the top cable end is a nice clean round cut. It was cut with a cable cutter. • The bottom cable was cut with lineman pliers.

Select the correct tool for the job. • This is one style of cable cutter. There are many available for varying cable types and sizes.

Introducing the PL-259 • Here is a solder-on PL 259 for RG-8 coax cable. • Crimp-on PL-259 connectors are also available as are ones for varying cable sizes.

The two most common cables. • Here you have two coils of cable. • The larger one is RG-8 which we’ll be working with today. • The smaller one is RG 58. • Both are 50 ohm cables.

Getting Started • A 140 watt solder gun with good pointy tip. • A good 60/40 tin/lead rosin core solder. • Solder with a diameter of 1. 2 MM or larger works a little easier.

Bench tools • A bench vise is handy if available. • Set of diagonal cutters. • Razor knife. • IT type scissors are handy to trim the braid when doing crimp-on connectors.

Preparing the cable – Part 1 • Determine how much insulation to remove from the cable. • Approximately 1 ½ inches will do. • Measure from the tip to about ¼ inch inside the collar.

Preparing the cable – Part 2 • Using a razor knife remove the 1 ½ inch of insulation. • Just score the insulation around the cable and bend. • DO NOT nick or cut the braid.

Preparing the cable – Part 3 • Carefully tin the shield to about 1 inch above the insulation. • Do not use excessive heat. • Smooth out the solder as much as possible without overheating.

Preparing the cable – Part 4 • Determine where the braid needs to be trimmed. • Use the razor knife to score a mark.

Preparing the cable – Part 5 • My tool of choice to cut through the soldered braid. • A plumber’s copper tubing cutter.

Preparing the cable – Part 6 • Carefully align the tubing cutter on your score mark. • Slowly run the cutter around the cable while adjusting it so that it only cuts through the braid and not the dielectric. • Do not squash the cable.

Preparing the cable – Part 7 • Use the razor knife to carefully cut down through the dielectric. • Do Not knick the center conductor. • Then carefully twist off the unwanted braid and dielectric.

Ready for the connector • The results of preparing the cable is to have the center conductor long enough to extend to at least the tip of the connector while having the tinned braid inside the holes and the insulator inside the collar. • Make sure there are no metal filing on the end of the dielectric.

Ready to Solder • Make sure you put the connector shell on first! • Slide the cable into the connector. • Screw the connector on until you see the tinned braid go in past the holes and the center conductor come out the tip. • You may need a pliers but don’t over do it!

Soldered and ready for shell • Solder the tip/center conductor. Trim if necessary. • Solder the braid to the connector body through the holes. • Make sure the solder flows but don’t overheat.

Inspect your work • Soldered connections should be shiny and smooth. • Insulation should not show any signs of melting. • Let the connector cool.

The final product • Screw the connector shell on and clean off any flux residue from the connector tip with a solvent, file, or knife.