If you are careful you can solder small wires directly to the copper-wire
contacts of the regular crimped-on RJ-11 plug.  This obviates the need to
strip the phone wire itself which, as you discovered, is a real pain.

  Foster


> -----Original Message-----
> From: piclist-bounces@mit.edu [mailto:piclist-bounces@mit.edu] On Behalf
> Of PicDude
> Sent: Tuesday, September 08, 2009 5:03 PM
> To: piclist@mit.edu
> Subject: [EE] RJ-11 wire/jacks/connectors?
> 
> 
> 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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> 
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