After deciding to use D-sub connector pins instead of directly soldering wires to the mini-DIN connector, the plug was very easy to build. The pins crimp on as normal with heat shrink for strain relief. Then the plug side of the pins were trimmed to the length of the mating mini- DIN pins, the trimmed D-sub pins are tinned with solder to fill the pin, and each pin is easily slipped over the mating mini-DIN pin with a touch of the soldering iron to the D-sub pin and a slight amount of push on the wire. No additional solder was needed. Since the pins are greater in diameter I used heat shrink over each pin for insulation. The rest of the mini-DIN plug installation is as normal.
Pins are too long for the housing
After tinning the crimped pins, a touch of the iron and it slides right on.
