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(captions coming soon...)
My wiring tools packed for a job - I've used this kit more in other locations than in my own workshop.
Set up at the workshop of Ahmad Dayes', wiring 11x AES-spec D-Sub 25pin assemblies, for Ahmad's brother Yussef.
Tascam pinout.
It's so pretty and colourful... but no one will ever see it!
I improvised a solder reel holder from scrap wood, some threaded rod and a nut.
I LOVE THIS!
We sacrificed a pair of spare D25 SCSI cables - using the severed connectors as a mounting jig to hold the new D25 connectors while we work and also to act as heatsink when soldering.
That's Ahmad in the background.
I can - and regularly do - stare at these photos... maybe a little too much.
Just before testing each assembly for continuity and no shorts.
Done! That was a long but fun shift. (The 2x stub ends were left as they needed to be wired as tails and the lengths and connector specs were yet TBC)
Bespoke console, made by Ahmad for Yussef.
D25 assemblies in position to make records!
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Busy event hire warehouse - improvised set up to manufacture multiple identical custom wiring assemblies for Portable Mains Distribution Box modifications.
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Assemblies to wire in 32A pass-through connection for single-phase and 3-phase distros.
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Examples of each of the 32A pass-through connectors.
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All the pass-through assemblies complete.
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Custom jigs made for distro modification project - the jig works for both 32A single-phase and 3-phase panel-mount cee-form connectors, reliably aligning the holes on each panel accurately.
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Close up of custom jigs.
"Temp jig" - a jig to make the "Master jig".
"Master jig" - used to make the "Production jig".
"Production jig" is safe to get worn out over time, preserving the "Master jig" whose purpose can be to make future "Production jigs" as and when they need replacing.
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Tool trolley ready for production line mods.
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Removing lid fasteners on each of x15 distros.
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15x distro lids off
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I love a production line project! All x15 distros ready for batch modification.
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Close up - pass-through outlet to be added on right of each distro.
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Armed and ready! Pilot hole twist drill.
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Jig - doing its thing.
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5x pilot holes, on each of x15 distros. 4x corner holes for fasteners and 1x centre hole for hole-saw.
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Twist-drill bit change - from pilot to clearance.
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4x clearance holes for fasteners, on each of x15 distros.
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To state the obvious, a hole saw.
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15x connector holes cut.
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All swarf vacuumed away.
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Holes sanded down - burrs/flashings/sharp edges smoothed down and made safe. I notice this process is all too often left out by other craftsmen.
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Nut-serts!! (Insert nuts)
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Hex bit extension for convenience.
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Installing nut-serts (insert nuts).
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Ready for pass-through assembly.
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1 of 15x 32A single phase pass-through assemblies, ready to install.
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The first pass-through connector installed, with insulated fasteners.
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New pass-through connector wiring to be incorporated into existing wiring.
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Existing incoming connector wiring before snipping on left; new pass-through connector wiring on right.
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Existing wiring snipped on left; new pass-through connector wiring on right.
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Wiring prepped ready for termination!
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Ferrules
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32A Pass-through wired in.
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Done and test passed! 15x distros modified with a single-phase 32A pass-through outlet.
An example of the kind of mains distribution products upon which I'd perform planned maintenance.
A typical day conducting annual service of distros for an event hire company.
Another typical day conducting annual service of distros for an event hire company.
Some custom distros aren't designed with easy neon-indicator-replacement in mind - one must entirely remove the incoming breaker, along with its mounting hardware, in order to replace the neon indicator.
Inside a portable 400A 3-PHASE Distro during annual service.
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