Looking for some ideas

[dmartech]

I am trying to create blocks for connecting multiple ethernet cables to switchports in network switches for testing. The way I created it is I plugged all 12 cables into the switchports then getting a thin piece of would to separate the top and bottom rows. I then placed glue on the the ethernet cables and let it dry. I wrapped gorilla tape all around the cables to keep it tight on the wood. Issue is since there is space between each end after a while of use the glue wears off and the cables break free from the wood. What can I do to keep the blocks as rigid as possible?

http://files.engineering.com/getfil...67-9a26-bf557c2e6be4&file=20121022_112010.jpg

http://files.engineering.com/getfil...08-8786-43eb7e6ca5ee&file=20121022_111953.jpg

http://files.engineering.com/getfil...0a-b8dd-9433c7c2a4d3&file=20121022_112001.jpg

http://files.engineering.com/getfil...1e-b80c-e07e00a39177&file=20121022_112215.jpg

 

[BrianGar]

Make sure cable bundle is tight. Maybe pour wax around it. Then from the top connector side, fill package with epoxy maybe?

Does it have to come apart again? _ever?

 

[dmartech]

No it doesn't ever have to come apart I'm looking for a permanent solution too keep it together.

 

[BrianGar]

Epoxy fill from front end then. Make sure no epoxy gets under the release tabs on the rj45s. Fill epoxy can be got with fine applicator tubes so it should be no bother.
I did similar once, on a bear of a prototype connector. Connector was about 120mm long, and 30mm high.

To save making a tool for the first shot - the 'plastic' that holds all cables in place like you are doing, I wrapped it all in copper tape, which also took up the shield braids. Filled it from ends as you have with epoxy, then placed in tool(to overmould) which I then filled via vacuum assist with a two pack silicone.

Connector was a once off, but looked and worked great. You dont need the over mould step obviously.
You could also break off all but the end rj45 holder/lock tabs on connectors for easy removal. Id say its in no hurry to fall out even with no tabs with that many connectors.

If you're filling, get a 30sec-60sec epoxy, and warm up tubes/can first, it will flow better. That way, if you have any small leaks, you'll only have drips for 60sec max.

Brian.

 

[dmartech]

Thanks Brian I will try that!

 

[telecomguy]

You might give Sugru a try...

http://sugru.com/

or some other hand moldable plastic...

https://www.inventables.com/technologies/hand-moldable-plastic