We spend so much time considering the construction of our speaker wire. How much time do we invest in considering our connectors construction? Most connectors I've seen have a serious design flaw and I’m just now discovering this.
I’m an Industrial Mechanic in charge of Special Projects at our plant in Las Vegas. Like any new project I’ve undertaken I’ve have to foresee every angle of a projects assembly from the very start all the way downstream to the finish. I’m about to make my first higher-end speaker wires when I discovered something rather alarming about the design and construction of MOST Banana plugs. Pay close attention. I want real advice and I want to bring this thing to your attention if you don’t already know it.
We like the mushroomed wire topped connectors because they securely hold our 12 awg wire in the plug. We sometimes buy wire in single stand for its conductivity/polarity characteristics and the fact that there is no opportunity of having two parallel conductor strands moving against each other regardless of how remotely a chance that might happen. But what about the male plug’s tips? You know, the little jackets that have multiple splits in them that run the length of the male plug and are fanned out and made to compress as they are pushed in their respective female seats? These bloody things are only loosely pressed on to the lug and this is a very not good thing. I’m looking at 3 different brands of plugs right in front of me and all of these things spin freely on their post. If I can spin these blades on the male post while inserted into the female connector (and I can) then my connections are technically severed. This is a horrible connection and would never be allowed in an industrial application yet we spend 20x times the money on speaker connection continuity than industry would ever spend on connectivity only to be installing un-foreseen connectivity "no-no’s” at both ends of our $100+ speaker wires.
Has anybody else here ever thought about this. It is just now something I’ve realized. In industry, if there were applications for the use of “audiophile grade” Banana plugs, every one that I have sitting in front of me would be tossed in a trash can. Yet audiophiles are more anal about connectivity than any industrial electrician. Am I way off base here?
I’ve seen a better male end in the GLS locking plug where a locking cam mechanism firmly presses the mail connector into the female confines but it has an inherent flaw in its design as well in the way wire locks into the upstream shank. Bare wire can rock side to side in the sleeve allowing stranded wire to slide on its self and solid connectors can slide on the connector’s sleeves. This introduces noise and fatigues wires.
I’d love to hear what you guys have to say about this before I build these expensive wires.