How to Assemble a BNC Cable

The Bayonet Neill-Concelman (BNC) connector is a common radio frequency (RF) connector used to connect coaxial cable in a number of applications. BNC cables are often used in cable and satellite television installations and in some older computer networking installations. Assembling a BNC cable is not hard. Making a BNC cable can save money and help clean up cable installations where an existing cable is too long.

Difficulty: Moderately Easy

Instructions

Things You'll Need:

• Coaxial cable
• Two BNC connectors
• Soldering iron
• Solder and flux
• A knife or wire stripper

Assembling the BNC Cable

1. Disassemble the first BNC connector by removing the back nut and removing the washer, gasket, ferrule, rear insulator, contact pin, and front insulator. BNC connectors are shipped properly assembled, so pay attention to the order in which the components come out of the connector.

2. Slip the nut, washer, and gasket, in that order, on to the coaxial cable.

3. Expose the coaxial cable brain by stripping about 10mm of the outer sheath from the cable.

4. Carefully fold the braid back over the remaining outer sheath of the cable. The braid should surround the cable sheath.

5. Slip the ferrule over the cable, then fold the braid over the ferrule to make a neat connection. Trim the braid as necessary.

6. Strip the insulation off of the center core. Leave about 1mm of insulation on the cable-side of the core.

7. Tin the exposed core by heating it and melting solder onto the core.

8. Trim the exposed, tinned core to around 3-4mm.

9. Place the rear insulator over the conductor core.

10. Put the conductor pin over the tinned core. This should be flush with the conductor core.

11. Solder the pin to the core.

12. Put the front insulator on the assembly.

13. Put the assembly into the body of the plug and tighten the rear nut.

Tips & Warnings

• Be careful not to damage the insulators with too much heat. Use just enough to melt the solder.