The following procedure goes over creating your own Ethernet cable. This process can be used to create both Category 5 & 6 cables. In this demonstration we used the 902-351 DIY Crimp Bundle. This is the perfect assortment of tools for someone learning to make their own network cables.
Step 1 – Spool out your length of cable
Pull out enough cable to run the length required for your installation. Be sure to allow enough to trim several inches off each end. It’s always better to go a little longer than to not have enough cable!
Step 2 – Strip off the outer jacket
Insert the cable into your wire stripper. In this demonstration we are using a round Cat 5 cable. If you use a flat cable then you need to use a stripper for flat cable. Most strippers designed for creating network cables can do either cable type. Rotate the stripper around the cable until the entire circumference of the jacket has been cut. Inspect the inner wires to make sure none of them have been nicked. If any are showing exposed copper wire then you need adjust your blade depth and try again.
Step 3 – Separate your wire pairs
Untwist all 4 pairs of wires and straighten them out the best you can. If there are any white fibers or a plastic divider in the center you can now trim it off.
Step 4 – Arrange wires according to diagram
Line up the individual wires in the order shown on your diagram. In our example we used the common Wiring Diagram B layout. Use your thumb and index finger to straighten out all the individual wires, while keeping a good grip to keep them in order.
Step 5 – Cut the wires
Cut the wires flush about 1/2″ from where the jacket was stripped off the cable. Make sure to leave enough that the ends of the wires are able to reach the pins of the connectors. The cable needs to go inside the connector housing enough for the crimp tab to come down on top of the jacket and hold it in place.
Step 6 – Insert wires into connector
Insert the wires into the connector. Make sure the connector is oriented properly, the release tab should be facing down toward the ground. Ensure all wires are still in the correct order after they are pushed all the way to the pins.
Step 7 – Crimp the connector
Insert your connector with the wire inside the 8P8C slot of your crimp tool. Give the crimp tool a good squeeze to ensure it goes through the full range of motion and creates a proper crimp. Pull your connector out of the crimp tool to show your finished connector. Repeat all of these steps to crimp a connector on the other end of your cable.
Optional: Test your cable
Use a modular/LAN cable tester to ensure all 8 wires are making connection.