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Further shorten the blue, blue-white, green, and green-white wires by about 1/16" This is so that the cable will be centered side-to-side on the Smart Sensor board.Shorten the solid color wire of each pair by about 1/8".Strip 5/8" of the outer and inner jackets on the other end of the cable.Attach the Molex connector as above, but using a Molex plug and female pins.Insert the stripped end of the cable through the hole in the bottle cap, going through from the outside of the cap.Re-insert the liner into the bottle cap lid.The cable will be a tight fit in this hole, and any sharp edges can nick or scrape the cable jacket. Drill a 1/4" diameter hole through the center of the bottle cap, and carefully deburr the hole with an X-acto knife.Using an X-acto knife, cut out a hole about 5/8" diameter in the center of the liner.Remove the soft liner layer from the inside of the bottle cap.Cut a 20 ft length of the cable and strip 3/4" of the jackets, as above.Inserting the pins into the Molex housing. Smart Sensor cable fabrication instructions
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Solder the wires to the Comm board, observing the correct polarity (black=com, red=12V).Insert the ends of the leads of the 9V battery clip through the PVC Inside Threded Pipe Plug.Position the 1/2" shrink tubing piece over then cut end of the jacket, so that any exposed bit of the foil shield is covered, then shrink it with a heat gun.Solder all the wires to the Comm PCB, with the wires coming in on the microprocessor side of the board, with the cable parallel to the board and coming off in the direction of the end of the board.
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Place a 5/8" length of 1/16" shrink tubing over the drain wire.Place a 1/2" length of 1/2" shrink tubing over the cable.Shorten the striped wire of each pair by about 1/8".
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