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K3LR method of installing a PL259 coax connector
  Published:2012-05-14 09:50:36   Views:

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.

Using silver plated PL259s makes this system a breeze. I only use Amphenol 83-1SP connectors. The connector body is silver and the shell is nickel.

You can get them from Mouser.
Take a fully assembled (shell + body) connector.
Measure the connector against the RG8 (or similar) coax.
Take the outer covering of the coax off with a sharp knife.
Pull the braid back all the way by fanning it out.
Wrap 3 to 4 turns of Scotch 88 black tape around the center conductor dielectric up against the fanned out braid.
Use wire strippers and remove the remaining dielectric from the center conductor.
Install the fully assembled PL259 onto the center conductor and over the 88 tape.
The back of the PL259 body should rest on the fanned out shield.
Solder the center conductor.
Fan out the shield and cut it to 1/4" long and fold over the back of the PL259.
Solder the shield all the way around to the back of the PL259 body.
While the back is still hot wrap 2 turns of 88 tape around the soldered shield
to seal it good.

There may be a small impedance bump that you might be able to see at VHF caused by this method vs. soldering through the holes, but the N4AR method guarantees a well soldered shield which is much more important to me.