Overview

These instructions are for preparing a cable to connect from a flash unit to an RCA jack on a trigger box. The flash unit must have a PC jack that will accept a standard PC plug. A typical jack and plug are shown in the photos below. Click on either image for a larger view.

The parts provided with the PC2 kit are listed below together with the tools that you need for assembly.

Preparing the PC cord

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The PC cord supplied with the kit is shown to the left. Using a pair of wire strippers, carefully strip back the cut end of the PC cord a distance of 1 inch. You'll see a copper sheath surrounding white insulation. Pull back the sheath and twist the wires together as shown to the right. Then strip back the white insulation to within about 1/8 inch from the black jacket. It's important to make sure there are no stray wires from the copper sheath that touch the other wire.

Next, you'll need the gray 2-conductor cable. From one end of the cable, strip back the gray insulation about 2 inches. Then strip back the red and black insulation about 3/4 inch. The result is also shown to the right.

Splicing the wires

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There are 2 sizes of HST, 3/32-inch diameter and 3/16-inch diameter. Cut the 3/32-inch piece into two equal lengths of 1 inch. Then slide them over the red and black insulation as shown to the left.

Next, twist the following pairs of wires tightly together as shown to the right: i) black wire and copper sheath ii) red wire and white wire.

Soldering the splices

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If you're using a soldering iron and are new to soldering, see the Soldering Tips below. The soldered connections should look similar to the photo to the left. Again, make sure there are no stray wire strands that could bridge from one splice to the other.

Soldering Tips Solder in a well-lit, well-ventilated, open area. Avoid contact with all metal surfaces on the iron. Keep the tip of the soldering iron clean by wiping it against a wet sponge or towel before and after each use. A clean tip should look shiny and silvery; any yellow or black material on the tip will get into the solder and may weaken your solder joint. Once the tip of your soldering iron is clean, touch a bit of solder to the tip just before use. This is called tinning, and helps the solder run more evenly. Heat the connection to be soldered by holding the soldering iron to it, until solder applied at the junction between the two melts and flows freely. This ensures the connection and the solder are both hot enough to yield a good solder joint. This should take no more than 10-15 seconds. After the connection is heated, try to get solder along the entire length of the connection by briskly moving the solder and iron along. Avoid touching only the solder to the connection, and then the soldering iron to the solder to melt it onto the connection. The connection will be cooler than the melted solder and won’t form a good solder joint. Let new solder joints cool for several seconds before examining them. There should be solder all the way around the connection, forming a rigid joint. When done, unplug your soldering iron and let it cool.

Shrinking the HST

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Slip each piece of 3/32-inch HST completely over the corresponding splice. Then, using a lighter or a match, move the flame smoothly back and forth along the entire length of the tubing, with the tip of the flame just beneath it. If you hold the flame too long in one spot or too closely to the tubing, you will notice smoke. If this happens, lower your flame and continue moving it back and forth. The tubing will visibly shrink, and will be acceptably tight-fitting after only 10-15 seconds of heating. See the results to the left.

Securing the splices

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Slide the 3/16-inch HST over the gray 2-conductor so that it completely covers the two spliced wires as shown to the left. Then use a flame as before to shrink the tubing. The result is shown to the right.