Elecraft KX3 Anderson PowerPole Adapter

thingiverse

This is a PowerPole adapter for the Elecraft KX3 Radio that (optionally) screws to the side of the radio to firmly attach your power cable to the radio and keep narrow gauge wire lengths as short as possible. It protects the power plug, prevents accidental shorting, and keeps the power cord from getting lost - all without interfering with access to any other radio function. This adapter is designed to be compatible with: - the stock KX3 radio - radios with custom end panels; and in particular the Side KX end panels - the Side KX clear lexan lid - the stock KX3 heat sink THIS ADAPTER WILL NOT WORK WITH ANY 3rd PARTY HEAT SINKS THAT I KNOW ABOUT, AND MAY NOT WORK WITH ANY OTHER 3rd PARTY UPGRADE. To build the adapter you will need: 1. Your 3D printed shell 2. A stock power cord from Elecraft, DigiKey, etc. 3. An Anderson PowerPole (15amp or 30amp) 4. A #4 x 3/8" machine screw (sorry, Elecraft does not use metric parts) Construction Steps: 1. Cut the power cord to length using the cutting jig 3D printed part. 2. Separate the 2 wire strands and strip ~5/16" (7mm) of insulation from the ends 3. Crimp or solder the bare wire ends into the PowerPole center contacts. Crimping is the preferred method if you have access to the proper crimper... 4. Insert the PowerPole center contacts into the plastic shells. MAKE CERTAIN THAT THE BLACK & WHITE WIRE GOES INTO THE RED SHELL AND THE SOLID BLACK WIRE GOES INTO THE BLACK SHELL. YOU WILL DESTROY YOUR RADIO IF YOU GET THIS STEP WRONG! 5. Test continuity and polarity. If you don't understand what this means or how to do it; you should probably purchase a pre-assembled unit. (See below.) 5. Carefully insert the cable and PowerPole assembly into the plastic shell. This is not easy. Tolerances are intentionally tight and you might break a few shells before you get the hang of it. I wedge the PowerPoles part-way into the shell and then insert the barrel plug. Once the barrel-plug is completely in place, I push (forcefully) the PowerPoles into position. **EDIT - 22 Jan, 2018 - In step 5 above, please note the orientation of the Red and Black PowerPole parts. THEY MUST GO IN THE SAME ORIENTATION AS THE PHOTOS! The red and black shells have slightly different dimensions. The fit is tight already, it will never seat well if you get it backwards.** A completely assembled and tested item can be purchased here: https://stores.ebay.com/n0wlradio