@harmonyards posted:John, I make test connectors similar to this for fuel injection harnesses, OBD2 testers, etc, etc, ….I use normal heat shrink tubing and clear silicone, ……put a dab around the header connector where the wires go in, slide the heat shrink up & over, wipe up any excess, wait about 15-20 minutes for the silicone to skin over, then shrink the tubing, when the silicone fully cures, it’s a tough, strong test plug that can be tugged on hundreds of times. …..sometimes I might use two sizes of heat shrink depending on the wire bundle …..one to surround the plug, and another that surrounds the wires neatly, but also bridges the larger one ….small tube of clear silicone is plenty cheap enough, and only cut a tiny hole in the tip so you can control ooze,….
Ding, ding, ding . . . I think we have a winner!
While I agree with John that this does not appear to be the precise solution shown in his pic, I think it is by far the best solution yet proposed to achieve the goal. Prior to final hardening, the silicone should be flexible enough to bind all the insulated wires and connector together into a single mechanically stable unit, as proven by Pat's success with the technique. The final result would no doubt look somewhat different than what was depicted John's pic, but for something that likely will *only* be visible when its mechanical properties are needed, ISTM silicone and shrink wrap should be an elegant and inexpensive solution.
