HD800 cable project.

[NightFlight]

It's too difficult to hand build a reliable connection with those terrible plugs. My cable breaks each time we take it to a Head Fi meet. They really need a molded plastic strain relief.

... thinking out loud ...

Since your 3/4 of the way there...

Since they can be disconnected, how about successively larger heat shrink layers, cut about .5 millimetre shorter each time and lined up at the top? Enough layers should help to keep that bend radius in check. Enough heat may even blur the line between layers.

The disclaimer being - I've never tried layering heat shrink.

 

[NightFlight]

http://www.doublehelixcables.com/store/index.php?main_page=product_info&products_id=139

 

[Doc B]

Looks like a big fat barrel with the same s****y little plastic connector pin thing inside. Soldering to those tiny little pins is the weak point. It melts way too easily and there is very little surface for solder contact.

 

[HF9]

Those pins are tiny for sure! Here's a pic of the Furutech HD800 connector interior compared to a dime: