Banana plugs

Is anybody else is having issues with 'Basket' style Banana plugs. They seem to be the normal these days, the design is also used in some Electric Foil fencing Body wires - I'm an Armourer. It doesn't take long for them to loose their springiness and give bad connections. We've just bought a load of much more expensive 'traditional' style ones. The basket ones are definitely a false economy, IMHO.
 
Absolutely agree, the old ones with a solid pin & a single springy wire last much longer. I've had to resort to bending some of the basket style ones to get a good contact.
 

Peter Sigsworth

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Is anybody else is having issues with 'Basket' style Banana plugs. They seem to be the normal these days, the design is also used in some Electric Foil fencing Body wires - I'm an Armourer. It doesn't take long for them to loose their springiness and give bad connections. We've just bought a load of much more expensive 'traditional' style ones. The basket ones are definitely a false economy, IMHO.
What do the 'basket style ones' look like? or 'traditional style' for that matter?- any chance of some pics of both types please. How about where you get your 'traditional ' ones from?
 
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Nick Mitchener

COMMITTEE
What do the 'basket style ones' look like? or 'traditional style' for that matter?- any chance of some pics of both types please. How about where you get your 'traditional ' ones from?

Not able to do pics at the moment but hopefully this makes it clear. Basket type have a rotating section on the stem made up of two complete bands connected by slightly bellied out strips. These make the contact inside the socket. The earlier style had a a slot in the pin with a single spring wire running along the slot.

I find that as well as losing their shape and reducing the quality of connection the annulus cut to accommodate the basket weakens the structure of the pin and the sharp edges are a point of fracture. Never had anybody break the old type.
 

Peter Sigsworth

COMMITTEE
Not able to do pics at the moment but hopefully this makes it clear. Basket type have a rotating section on the stem made up of two complete bands connected by slightly bellied out strips. These make the contact inside the socket. The earlier style had a a slot in the pin with a single spring wire running along the slot.

I find that as well as losing their shape and reducing the quality of connection the annulus cut to accommodate the basket weakens the structure of the pin and the sharp edges are a point of fracture. Never had anybody break the old type.
From your description, I searched google and cut and pasted the found images - simples.
OK so this is the basket type:

1617176606746.png
and this is the traditional/old type:
1617176685652.png
Is that what you mean? - Any ideas where we get the old type cheaply from as all our suppliers sell the basket type
 
Is anybody else is having issues with 'Basket' style Banana plugs. They seem to be the normal these days, the design is also used in some Electric Foil fencing Body wires - I'm an Armourer. It doesn't take long for them to loose their springiness and give bad connections. We've just bought a load of much more expensive 'traditional' style ones. The basket ones are definitely a false economy, IMHO.

From your description, I searched google and cut and pasted the found images - simples.
OK so this is the basket type:

View attachment 5881
and this is the traditional/old type:
View attachment 5882
Is that what you mean? - Any ideas where we get the old type cheaply from as all our suppliers sell the basket type
The problem that I have found is that the plugs are made by someone who has seen one described but does not actually use them - a common problem.

In the case of the 'basket' type, the basket makes a wiping contact with the socket (thus breaking through any oxide or other crud on both mating surfaces) it is then firmly retained under the pressure of the spring basket. So far, so good, this is exactly what is required.

The problem is with the connection between the basket and the rest of the plug. If the basket is a loose fit (as is the case with the type illustrated) oxide builds up on the not-quite-contacting surfaces and the connection eventually fails.

In the case of more reliable ones, the basket is a tight fit on the pin so that any movement wipes away the oxide, also the connection between the basket and the pin is held under pressure.

Basically it is a design (or failure to design) problem; I have never found a way of tightening the basket, the only solution was to scrap the leads and replace them by ones at twice the price.
 

Peter Sigsworth

COMMITTEE
The problem that I have found is that the plugs are made by someone who has seen one described but does not actually use them - a common problem.

In the case of the 'basket' type, the basket makes a wiping contact with the socket (thus breaking through any oxide or other crud on both mating surfaces) it is then firmly retained under the pressure of the spring basket. So far, so good, this is exactly what is required.

The problem is with the connection between the basket and the rest of the plug. If the basket is a loose fit (as is the case with the type illustrated) oxide builds up on the not-quite-contacting surfaces and the connection eventually fails.

In the case of more reliable ones, the basket is a tight fit on the pin so that any movement wipes away the oxide, also the connection between the basket and the pin is held under pressure.

Basically it is a design (or failure to design) problem; I have never found a way of tightening the basket, the only solution was to scrap the leads and replace them by ones at twice the price.
How do we know if the plug is a better quality tighter fitting 'basket type' connection? Price is not always a good indicator as the shroud may be better quality and the basket part just a poor as the competition.

Can anyone, from experience, recommend a make/supplier?
 
How do we know if the plug is a better quality tighter fitting 'basket type' connection? Price is not always a good indicator as the shroud may be better quality and the basket part just a poor as the competition.

Can anyone, from experience, recommend a make/supplier?

I only buy these, others sell them but SciChem are currently the cheapest.

https://www.scichem.com/product/plugs-stackable-4mm-black-ela140010
(Search "4mm stackable plugs" for the other colours).

(I think this thread will probably now descend into the 'it's cheaper to buy ready made leads' conversation. Again). :p
 

clairelucas

COMMITTEE
While on the subject(ish)-
I usually can remove 'stuck' broken off banana plug ends from the power pack, as they tend to come away and still have a 'grabbable' part I can lever out with fine forceps. I now have one that appears to just have the solid metal part stuck- no part to grab/lever that i can manage. Any ideas of how to get the b^$&r out?
 
Absolutely agree, the old ones with a solid pin & a single springy wire last much longer. I've had to resort to bending some of the basket style ones to get a good contact.
a good way to get them to make a contact is get a small spatula underneath and twist them slightly to make a higher peak.
 

Nick Mitchener

COMMITTEE
While on the subject(ish)-
I usually can remove 'stuck' broken off banana plug ends from the power pack, as they tend to come away and still have a 'grabbable' part I can lever out with fine forceps. I now have one that appears to just have the solid metal part stuck- no part to grab/lever that i can manage. Any ideas of how to get the b^$&r out?

Last time I had one like that I drilled a hole in it and put a screw in to pull it out. I encased the whole power supply in plastic to stop any swarf going inside the power supply.
 

clairelucas

COMMITTEE
Last time I had one like that I drilled a hole in it and put a screw in to pull it out. I encased the whole power supply in plastic to stop any swarf going inside the power supply.
I did ask the tech technician with this in mind (I don't have the tools), but didn't get a lot of enthusiasm! Was it difficult to drill- seems so small and hard/undrillable..
Cheaper then new power pack, and seems a ridiculous (embarrassing) thing to send for repair!
Thanks..
 

Nick Mitchener

COMMITTEE
I did ask the tech technician with this in mind (I don't have the tools), but didn't get a lot of enthusiasm! Was it difficult to drill- seems so small and hard/undrillable..
Cheaper then new power pack, and seems a ridiculous (embarrassing) thing to send for repair!
Thanks..
It was a philip harris spacesaver case so to get it to sit more easily on the bed of the pillar drill I took the top and bottom off and wrapped it all in plastic. I wasn't sure it would work, I though the pin might just rotate with the drill but it actually worked really well. I got enough of a hole drilled so that I could start a self tapping screw in the end of the pin and pull it out.
 

clairelucas

COMMITTEE
I've just done the same- borrowed the DT techs Dremel. Came out well on about the 4th attempt (previous ones just seemed to be drilling a smooth well in the end), pleased it worked in the end!
Thank you!
 
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