Hakko FX-888D DIN Jack Repair / Upgrade Adapter
Description
The DIN jack in my Hakko FX-888D soldering station got really flakey. Maybe the plug on the iron's cord was flakey too. Either way, the connection was terrible. The plug wiggled loosely in the jack, and wiggling it with the iron on would result in the temperature reading jumping up and down, or it would lose the connection entirely. Cleaning the contacts would only help for a little while, the problem would always come back. I decided to replace both the jack and the plug with high-quality DIN connectors. This printed part is a small adapter/insert to make the new jack fit perfectly and look great. After this upgrade you'll have a much, much more robust jack with virtually no play, and you can use a lock-ring to prevent the plug from being pulled out. The adapter frames the component nicely on the front panel and looks factory-quality. The built-in jack is a 6-pin DIN (240 degrees) connector, however the center pin is not connected to anything (if you look closely, the center hole doesn't even have a metal contact in it). So the jack can be replaced with a 5-pin DIN (240 degrees) connector. In fact, the one I used (61HA5FX) also has a blank hole right in the middle, which keeps it fully compatible with an unmodified FX-8801 iron's 6-pin DIN plug. I wanted mine to have a lock-ring, so I replaced the iron's plug too; the stock plug on the iron is low quality and mine was making poor contacts in the jack. Components: - Switchcraft 61HA5FX ([Digi-Key SC1823-ND](https://www.digikey.com/product-detail/en/61HA5FX/SC1823-ND)) - Optional: Switchcraft 12CL5MX ([Digi-Key SC1509-ND](https://www.digikey.com/product-detail/en/12CL5MX/SC1509-ND)) - 2x M3 x 8mm pan-head machine screws - 2x M3 nuts Notes: - The FX-888D is extremely easy to take apart, and there are step-by-step guides available elsewhere. - Make good notes (or take good pictures) of the colors of all the wires before cutting any of them so you can re-solder them properly to the new components. - After printing the adapter, place it in the existing cutout in the panel on its own and then use it as a template to drill two 3mm holes through the plastic front panel for the machine screws to go through. - Remember to thread all the wires through the panel and the adapter before re-soldering them to the new jack.
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