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molex replace with powerpole:


Remove the molex connector by pressing on the side tabs and pulling it into the radio. It's a pretty loose fit
so this was surprisingly easy. Often molex are in very tight in sheet metal and this is a serious fight.

The individual pins are pretty easy to remove from the housing. Using a small, narrow flat blade screwdriver,
press the locking flanges on each pin in toward the pin while applying a little pulling pressure. Do this for
each of the two flanges on each pin and you should have it out pretty quickly. Just pull lightly.

This leaves a hole in the frame that's just slightly too narrow for two PP45 housings, but the doubling up
of the power pins was overkill. (possibly to prevent the intermittent issue) So this leaves us with a pocket
on the outside about 18x30mm. I will be cutting a piece of smoked plastic that size and making a 8.5x16.5mm
hole in that to fit in a PP45 housing. I'll hot-glue the housing to the plate, then use hot glue to affix the
plate into the back of the radio. (from the outside) I might also fill in more hot glue on the inside to
provide better mechanical support.

01 evil molex has to go	02 molex plug detached	03 molex cubby is 18x30mm	04 plenty of power wires	06 powerpole plate is fabricated	07 ready to receive
08 plate fits nicely	09 hot glued from the inside	10 hot glued from the inside	11 replacement complete

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last updated 03/17/2025 at 07:05:28 by make_www_index.command version 2025.03.04.A