I made a beta cable for my tech shop using an original SD2 cable set. I intend on making up a couple of more sets in the coming couple weeks... but this time beefing up the cable to take a bit more abuse. My intent is to use 20 or 22 Ga. for all the DB25 / DB9 connectors and 18 GA for all other conductors. I will be making the cables with full strain relief at all joints to resist pulling the conductors out in case of tripping. Cable sheathing will be expanded nylon mesh and all multi-conductor cables to be fully shrink wrapped. All the Tyco Superseal connectors will be fitted with rubber boots to provide additional strain relief protection.
My techs frequently take their SD2 in the car so they can record data while in motion. So they wanted the cable long enough to position the SD2 on the passenger side and not get under driver's feet. That will require cables at least 5 feet long from the OBD2 plug to the DB25 / DB9 plug.
No way can I make it as bulletproof as Brian did, but from looking at the original set my techs have, it is no wonder that mere trip over one of the cables can result in pulled pins and such.
One problem is that the serial plugs (DB25 and DB9) can only accommodate a max size of 20 gauge wire ... not enough room in the plug shell to put anything larger. This is not a problem when you have a bundle of several wires as the combined strength of the resulting bundle is quite high. But when you breakout the conductors into say 3 core conductors, the strength becomes compromised. So have to use strong sheathing or other means to provide strain relief. I saw on some original cable sets that there was no strain relief whatever on the Tyco connectors ... relying entirely on the crimp connection to the male or female pins and sockets.
So, as I was saying, I can put together a cable set at my kitchen table in about an hour or so ... and since I am retired with time on my hands, I thought I might feel the waters, so to speak.
If someone has interest, drop me a line. I have not set any kind of a price but am thinking of something like $500 for the full set. That will give you DB9, ADC, IS01, IS02 and the CAN plugs connecting to the DB25 end for one set ... and A thru F Tyco connectors plus the 12v power plug on the ODB2 end.
Last edited by bisel; 11-11-2013 at 08:04 PM.