Imagine, Discover, Invent ... Electronica [IDI]: How to Make an Ethernet Cable Without a Crimping Tool

DISCLAIMER: Making an ethernet cable without a crimping tool will require the use of a sharp-edged tool and the application of force. This could potentially cause injuries. Follow this guide at your own risk.

First of all, you should always use a crimping tool to ensure that the wires make good contact and are physically secured to the connector. You should only make cables without a crimping tool temporary solutions.

Materials

- Cat5e or Cat6 twisted pair network cable

- RJ-45 connectors (buy more than 2 in case you mess it up)

- Swiss army pocket tool or screw driver with thin edge

- A small blade or scissors

Step 1: Make a small cut to the CAT5e until the pull string is exposed.

Step 2: Pull the string to cut the sleeve and expose the wires.

Step 3: Then cut the remaining piece of sleeve and pull string until we are left with the wires only.

Step 4: Arrange the wires in the correct order to create a standard or crossover cable and slide the cables into the RJ-45 connector.

Next, we'll need to press two parts in the RJ-45 connector. In the photo below, #1 is a tab meant to put press and hold on the wires to prevent them from coming off. The metal pins in #2 down must be pressed down until they pierce the wires' sleeves in order to make electric contact.

Step 5: Using the flat edge of our tool, press down the tab in #1 until the wires are secured.

Step 7: Using the same tool, press each of the pins until they go through the sleeves of each wire. Holding the tool in a horizontal position (like cutting a cake) will give you more control than pressing it vertically. I'd also recommend using a soft surface, like a newspaper, to prevent the connector from sliding. If you accidentally bend the plastic edges between pins, you can use a sharp edge to straighten them up.