1. How To MakeCategory5/Cat5e orCategory6/Cat6 Patch Cable
2. Before we start making a cat5e/Cat6 patch cable, need to cut a stranded length ofCat5e/Cat6. After cutting the length you should make sure to measurement.Nothing is worse than the patch cable you just built being an inch too short for yourapplication. After cutting the desired length we will start building our patch cable byshedding back about 1 inch of the jacketAfter striping make sure that the depth of your stripper is set deep enough to cutthe jacket but not so deep that it nicks the conductors of cable. If you do nick theconductors while stripping the cable, the cable may work fine at first, but after timethe conductors will break, or even worse, begin to short out.
3. Now that we have the jacket stripped back well want to separate and straighten the pairs. Wellstart by pulling the first pair and the last pair to their respective sides (Orange to the left andBrown to the right). Untwist these pairs making sure not to untwist the cat5e/cat6 plenum cableany further than youve stripped back the jacket. Now well split the green pair. Pull thewhite/green conductor to the left and the green conductor to the right. This leaves you with theblue pair in the middle. Untwist the blue taking care to ensure that the white/blue conductor ison the left and the blue conductor on the right.Note: Normally, it would be unmentionable to untwist the Cat5e/Cat6 pairs, except whenbuilding patch cables. It would be almost impossible to insert the conductors into the properconnector locations without untwisting. (Keep in mind you want to keep as much of the twist ofeach pair intact in order to meet performance standards.)
4. Now that weve separated and straightened the pairs we need to arrange theconductors in the proper order according to which wiring standard you are using. Forthis example we will be wiring via the 568-B standard (most common in patchcables). Please consult the pin-out for the proper color codes. After you have thewires arranged, place them tightly together as show in the picture to the right. Oncethis is done, verify that the wires are still in the proper order and continue to step 4.
5. Now we need to trim the conductors down to fit into the RJ45 connector. While trimming, makesure you make a nice clean cut at a 90 degree angle about 1/2 of an inch from the end of thejacket. If you fail to make a straight cut, some of the conductors may not reach the connectorcontacts. If you cut the conductors too short, again they will not make contact. If you leave theconductors too long, when crimping the connector, the jacketing will not be gripped leaving thestrain on the conductors. This is not a good situation! For proper trimming, hold the wiressecurely just at the end of the jacket as shown in the picture to the left. Be sure to keep theconductors in the proper order.
6. Our Cat5e patch cable is almost done. While still holding the cable firmly, we now need to placethe conductors into their proper location in the RJ45 Cat5e/cat6 Modular Connector. Hold theRJ45 modular plug with the contacts facing up (towards you) and carefully insert the conductorsin their proper locations. Apply a moderate amount of force in order to properly seat the wiresagainst the contacts in the connector. When the wires have been correctly inserted into theRJ45 modular connector, observe the tip. As illustrated in the picture to the left you should beable to see the end of each conductor, indicating that the conductors were fully inserted. Also,take note of the colors. All whites should be on the top and all the colored conductors on thebottom. Once this is achieved, continue to Step 6.Update 10/03/2007:Many customers have reported that they find Cat5e/cat6 Connectors with load bars mucheasier to use during the termination process. The load bar is used to align the conductors intothe proper order and hold them in place during insertion.
7. Carefully insert the assembly which you have just completed into a modular crimping tool,taking care to verify the conductors stay fully inserted. When crimping the connector, use thefull stroke of the crimp tool so that the contacts properly "bite" into the conductors. After youhave completed the crimp, take time to look at the connector and make sure all the pins werecrimped and that they made good contact with the conductors.
8. If you are building a straight through (standard) Cat5e/cat6 patch cable, terminate the oppositeend by repeating this process from step one. If this will be a cat 5/ cat6 crossover cables, returnto step one and continue; however, terminate the other end of the cable using the wiringscheme that you did not use for the first end. Terminating one end with 568-B and the otherwith 568-A creates a crossover cable. If it is a straight through cable you are making, simply usethe same wiring scheme for both ends.
9. Thats it! Use a tester to test for continuity and your diy Cat5/Cat6 patch cable iscomplete.Note: If the cat6/cat5e plenum cable does not test positive for continuity cut theconnector off and start over, or buy one of our pre-made or custom length patchcords.