Hi all,

I need to add an RJ-11 connector to an existing product (prob 100-200
units).  The PCB is tightly enclosed already so I can't add an RJ-11 jack on
the board.  I can solder wires to the board though, and let the connector
dangle outside the enclosure.  This can be a plug rather than a jack, as I
can supply an RJ-11 F-F adapter.

As a test, I sliced a generic RJ-11 phone cord in half and soldered the
wires to pads on the PCB, but the wires break very easily.  Even just the
movement from re-enclosing the PCB in the enclosure causes some wire
breakage (right at the PCB pads).  Anyone know if there are different grades
of phone-cord wires, one of which may be less breakable?  I'm not sure if
hot-gluing the PCB right around the pads would be a reliable answer, but I
will experiment with that.

FWIW, stripping the wires was a pain too (cut the wires many times) so I
finally just trimmed all of them, and heated the ends with a soldering iron
to melt the insulation back a bit.  Is there a better way to do this?  Or if
anyone knows of an RJ-11 connector with some type of 4-pin header-type
connector on the opposite end, that may be a good answer.

What about an inline jack?  Anyone have links to one with solder points?  I
can then use regular (stronger) wires.  I've seen them used in commercial
products, but can't find them individually as a component anywhere.

Thanks,
-Neil.


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