I would solder to the board, and then a short piece of CAT-?  to a RJ-11 
male >> Female/Female, or a Female RJ. Possibly can find a RJ female 
that screws or otherwise fastens to a little board that can be fastened 
(Velcro cheap) to your existing enclosure. Then a RJ-? plug can easily 
and reliably be inserted/removed. The CAT-?? comes solid and stranded 
(more flexible) wire, and round or flat jacket. Match the males with 
those criteria. The males crimp easily with a cheap tool. The females 
come with punch down, or tool less crimp, just a pair of pliers.  Solder 
makes a connection prone to fatigue failure, anchor the cable a short 
distance away with a tie rap, grommet, or cable clamp. Most of these 
RJ's don't require stripping, just remove a bit of the jacket, insert 
the flattened unstripped ends and squeeze.

PicDude wrote:
> 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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