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What do people do for building or sourcing custom inline fused power cables? #parts #power #supply #12v

 

Hi all,
I'm a new ham trying to build a power supply cable like this for my QDX or QMX+ to use my existing battery in the field:
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> 18AWG cable w/ ring terminals > inline home-brew buck converter > 18AWG cable > fuse (1.5A?) > 18AWG cable > 2.1mm barrel connector
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The part in bold is what I'm having trouble finding an obvious solution for. Is there a way hams typically build such fused cables without a whole lot of extra splicing? I feel like I'm missing something because I don't see much discussion about this or any pre-made assemblies like that. Sources for such an assembly would also be appreciated.
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I saw this thread but ordering from UK to US and cutting off the Powerpoles isn't a good option.
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Here's some we're doing if anyone's interested in that.
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Thanks, Mike
 

It is infinitely worth your time to learn to solder and/or crimp, and to go ahead and get the equipment to do so. It's a small investment and if your doing ham and/or electronics projects you will need cables, it's really just a matter of getting the components and connectors and putting them together how you need

 

Here's a barrel jack, 12awg:
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Here's a 16awg in line barrel fuse :
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I know their not 18awg,and that you might not want to buy it off Amazon, but at the least they can give you a starting point of search terms.?
 

Don't remove the powerpoles from that lead, add Powerpole connectors to your battery, and everything else that needs or uses low voltage power.? Pairs of connectors can be assembled handed and so make connecting a supply the wrong way round much less likely.
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I have a constant Voltage and Current buck/boost regulator with PowerPoles and so can hook this up to provide regulated power with the voltage and current limits of my choice from a variety of sources to anything.
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Getting cable and even some basic crimpers and connectors is fairly easy. I'm in the process of setting something up for a go kit right now and loving my Wirefy () for making some quick connectors. You can do most things even without solder if that part is sketchy for you (although you can get good at soldering very fast with practice, too!).
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Thanks all for the quick input.
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Jason wrote:
Here's a 16awg in line barrel fuse :
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I know their not 18awg,and that you might not want to buy it off Amazon, but at the least they can give you a starting point of search terms.?
Thank you, that's what I was looking for! 16awg is fine. Will look for that kit off Amazon. I ordered the barrel connector from QRP Labs when I got the radio.
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On Fri, Apr 11, 2025 at 12:56 PM, Chris, G5CTH wrote:
Don't remove the powerpoles from that lead, add Powerpole connectors to your battery
The main problem with that cable is that it's expensive and across the ocean, and I do have powerpole cables for the battery, but the barrel connector will be on the other side of the buck converter. Fair enough though, it's worth considering terminating the cable out of the buck converter with powerpoles too for versatility. I just don't think I'd have another need for a strictly regulated 12V source so I was thinking of this as a dedicated cable and was trying not to put money into powerpole tools at the moment.
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On Fri, Apr 11, 2025 at 12:05 PM, Sean [AK6BM] wrote:
It is infinitely worth your time to learn to solder and/or crimp, and to go ahead and get the equipment to do so
Yes, I know how to solder and crimp. I have a crimper for butt connectors and the like. It's the "getting the components and connectors and putting them together how I need" that I'm primarily asking about. I just don't want to have more splices than necessary.
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On Fri, Apr 11, 2025 at 10:31 AM, <k3loe@...> wrote:
trying not to put money into powerpole tools at the moment.
I see your point, good crimpers are expensive.? This is one of the reasons I prefer soldering.? My one soldering iron works with all sizes of cables.? Also making a good crimp joint requires that the wire, crimp ferrule, crimp dies and crimper are all compatible.
 

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I solder all of my power pole connectors, easy to do and IMO a superior connection, last thing I want in the field is a shaky connection.

John
KK4ITX?

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