The Micro-Fit were the smallest-footprint panel-mount connectors that I could find that are oriented, can carry 3 Amps, and cannot be easily shorted by a flying metal part. The other contenders were 5.5mm Barrel jack (can easily be shorted, and are generally crap,) and Mini-XLR (unshrouded pins, easy to short as well, and larger footprint.)

The Micro-Fit protrude a little bit, which I’m not a fan of, so I recessed the control panel. 3/

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The original power supply is split in the middle and held by clips. Nobody wants that, so I made a flat base and a cover, and added holders for heat-set threaded inserts.

In addition to the 24V for the TS-101, I need 12V for the fume extractor. In order to avoid accidentally swapping the power cables, I chose 3-pin panel-mount Molex Micro-Fit connectors, and I’ll connect 12V and 24V to different pins. 2/

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I’m having a blast CADding this project in OnShape. It’s a new case for the power supply of my TS-101 soldering iron, with switches and connectors to plug detachable cables for the TS-101 and the fume extractor.

I started with a mock up. Then I CADded the original power supply, and finally modified it to add the control panel. 1/

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