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Repair Design Line retractable handset cord plug (H4DY cord)

Started by paul-f, March 24, 2013, 01:55:52 PM

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paul-f

The cords used on models like the Stowaway and Telstar are thin and fragile - often resulting in intermittant connections (crackling sound) or no audio.

The plugs used are quite interesting with built-in strain relief.  Unfortunately, they are now almost impossible to find, as are NOS cords for replacement.  Occasionally a 5C cord reel turns up or a damaged set can be used as a parts donor.

As a last resort, the plug can be replaced with a standard modular handset plug.

Here are some photos showing the original plug parts and a repair I did in 2003.  My, how time flies.

Stripping, separating and getting the conductors in the proper holes in the plug require an unusual amount of manual dexterity.

Since the original strain relief plugs are usually not available, the repair includes a standard modular plug.

If the original boot is damaged beyond repair, I have used shrink tubing.  It's obviously not as good as the original, but sufficient for display and occasional use.

More background is in this topic:
http://www.classicrotaryphones.com/forum/index.php?topic=9048
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