How to Make a BNC Cable Using Solder and Clamp Connectors

BNC cables are coaxial cables with BNC connectors, offering a strong and reliable connection commonly used for video and RF signals. There are several ways to attach these connectors, but two are most common: the solder and clamp method, and the crimp method. This guide covers the first, with a step-by-step process for assembling a BNC cable using soldering and clamping techniques.

Cut the cable to the required length, keeping in mind the "cut length." This is crucial, as the required cut length may differ based on the reference point for the overall length and the connector's internal dimensions. When the cable length is short or used in measurement applications, precision is especially important.

・ If the total length is measured from the tip of the connector, the cut length will be shorter.
・ If the total length is measured from the base of the connector, the cut length will be longer.

Slide the clamp, washer, and gasket onto the coaxial cable in that order, then cut the outer jacket as shown in the cable mounting diagram. Ensure the stripped dimensions match those specified in the mounting specification sheet. If using a knife, it may help to mark the cable beforehand. Next, slide the clamp onto the exposed outer conductor (braid) side, and unbraid the outer conductor. This step is crucial for the next stages.

Align and fold back the outer conductor (braid) that was unbraided in the previous step, then cut the insulator according to the cable mounting diagram. Ensure the insulator dimensions match those in the mounting specification sheet. After folding back the outer conductor, use nippers to trim it just slightly shorter than the clamp. If cut too short, the cable may loosen; if too long, the shell may not fit correctly and the center contact may be pushed down.

Attach the center contact to the inner conductor (core wire) and solder it securely. Ensure the solder does not bulge and there are no gaps between the center contact and the insulator. Soldering requires precision to avoid defects like "cold solder joints," which can occur from excessive solder, high or low temperatures. These defects can cause trapped air or rough surfaces.

At Tyclon, we conduct an internal soldering test, and our skilled technicians perform careful soldering. Afterward, the contact is pulled with radio pliers (about 1 kg of force) to ensure no issues. We also use dedicated jigs to hold parts in place for precise and stable soldering.

Attach the shell and raise the fastening fittings. Tighten with a spanner or nut to complete the assembly. A slight tightening sound from the internal gasket signals that the process is complete. If you're unsure when fastening is finished or need to meet a specific torque specification, please contact us. At Tyclon, we use dedicated jigs to make tightening easier.