A lot has been written over the years about the correct way
to install PL259 connectors on coaxial cable. Entire flame wars have
taken place on the internet and on-air about this delicate and often
Regardless of the method used connector failures almost always are
the result of bad solder work. To weld the braid side of the coax to the
connector is neither simple nor ordinary soldering. Probably a third or
more PL259s I've replaced had bad connections to the braid.
However, there is an easy way to install these connectors that
totally eliminates the need to solder braid or solder to the connector
housing. This greatly reduces the risk of cold solder or overheat damage
to the coax.
My project was to make a patch cord to go between my radio
and SWR meter, which is hooked up only for testing. To make handling
things easier I decided to use .6 meter (2 feet) of RG8-X coax which is
about half the diameter of RG8. I thus needed an adapter for the PL259
Connectors used to hook to my radio and SWR Meter.
The connectors and the required adapters are shown at the left. The
smaller adapter tubes screw into the back of the connectors to take up
the size difference in the cables. There are adapters for several cable
sizes, make sure you get the right ones for your coax.
Step 1: Strip the outer insulation of the coax for about
3/4" (the length of the adapter tube).
Step 2: Flip the exposed braid back over the insulated part
of the coax. Be careful doing this as the braid has to lay smoothly over
the coax or the next step will be impossible.
Step 3: Force the coax into the adapter so that the braid is
inside the tube as shown. The front edge should be even with the inner
edge of the adapter tube. The easiest way is to treat the coax like it's
threaded and twist the adapter on using downward pressure.
Step 4: Dress the inner conductor of your coax as shown.
There should be only a small amount of the inner insulation left
projecting forward from the end of the adapter. Tin but do not cut the
center conductor at this time.
Step 5: Assemble the connector. First slip the threaded
outer sleeve over the cable. Next making sure the center wire goes
through the center pin of the connector, screw the adapter into the back
of the connector housing. Tighten the adapter with pliers. Finally,
solder the wire into the connector's center pin.
Step 6: Clip away the excess center wire and spin the outer
ring forward over the connector housing and the connector is now ready
All I had to do was repeat this on the other end of the coax and my
patch cord was complete. I performed 2 final checks... First, I tested
the cable for shorts and continuity with an ohmmeter then, to be extra
sure, I hooked it up between a dummy load and my SWR meter and tested it
at 50 watts. I got a 1:1 SWR, telling me the cable is good.
A similar process can be used with full size RG8 cable as well.
- Strip off 3/4" of outer insulation.
- Fold the braid back over the coax.
- Cut away the inner insulation close to the edge of the braid,
exposing the center wire.
- Tin but do not cut the center wire at this time.
- Slip the outer ring onto the coax.
- Twist the connector housing onto the coax, over the exposed braid.
- Solder the center pin and cut away the excess wire.
- Bring the outer ring forward and you're done.
I've come to trust this method and it's very simple. Yes it's
cheating, but it does work. I've done CB, Amateur and other
installations this way and while I still had the occasional connector
failure, I'm confident I had fewer than I would by relying on a solder
spot through the side of the connector housing for my grounds.
It works, it's easy... give it a try!