How to Assemble a PL-259 Radio Connector

Welcome to our quick-start guide for assembling a PL-259 radio connector. 

What is a PL-259 Connector?

The PL-259 is a rugged, male RF connector designed to mate with SO-239 female connectors. It's commonly used in amateur radio, CB radio systems, VHF communications, and other RF applications.

Key Benefits:

• Threaded coupling for secure connections

• Compatible with RG-8, RG-213, RG-58, and similar coaxial cables

• Simple to assemble with basic tools

Tools & Materials You'll Need

Recommended Tools:

• Soldering Iron (30–60W): For precision and adequate heat.

• Solder (rosin-core, 60/40 or lead-free): Ensures solid electrical contact.

• Coaxial Cable Stripper or Utility Knife: For clean, controlled cable prep.

• Wire Cutters: For trimming the coax and braid.

• Needle-Nose Pliers: Helpful for adjusting the braid or center conductor.

• Multimeter: To test continuity and avoid shorts.

• Heat Shrink Tubing or Electrical Tape: Provides insulation and strain relief.

Materials:

• PL-259 connector

• Coaxial cable (sold separately)

Step-by-Step Assembly Instructions

1. Prepare the Coax Cable

• Cut the end of the coax cable cleanly with wire cutters.

• Strip the outer jacket approximately 1 to 1.25 inch from the end. Take care not to nick the braided shield.

• Fold the braid back evenly over the remaining outer jacket. Ensure it’s not frayed or overlapping the center dielectric.

• Strip the dielectric to expose about 1/4 inch (6 mm) of the center conductor.

• (Optional): Tin the center conductor with a thin layer of solder to help it insert smoothly into the connector pin. 

2. Fit the Connector

• Slide the backshell (sleeve) over the cable before inserting the connector. This is a common mistake to forget!

• Insert the cable into the connector body until the center conductor emerges through the pin and the braid makes contact with the connector’s metal shell.

• Ensure the dielectric sits flush and the braid makes contact inside the connector shell for proper grounding.

3. Solder the Connection

Center Pin:

• Apply the soldering iron to the center pin.

• Feed solder into the hole on the tip of the pin until it fills and bonds with the conductor. You only need to fill the end of the center pin, it is not supposed to be completely filled with solder, otherwise you can and usually will over heat the center pin. 

Shield/Braid:

• Solder through the holes on the side of the connector body (typically 2–4 holes).

• Hold the soldering iron against the hole and insert solder so it melts onto the braid underneath. Sometimes scraping the area around the holes is helpful for soldering.

• Repeat for all holes to ensure full 360° electrical contact.

Cool Down:

• Allow the solder to cool naturally. Avoid moving the connector during this stage to prevent cold joints.

4. Final Assembly

• Check for stray braid strands touching the center conductor and trim as needed. This is common to have strands shorting your assembly, don't let it happen. 

• Screw the backshell onto the main connector body securely. You did remember this step, right? :)

• Apply heat shrink tubing or wrap electrical tape around the connection for extra support and weatherproofing if desired.

Quality Check: Test Your Work

Use a Multimeter to ensure everything is correctly assembled:

• Center pin to center pin (end to end): Continuity (✔️)

• Shield to shield (end to end): Continuity (✔️)

• Center to shield: No continuity (✖️) — indicates no shorts

Use an SWR meter or antenna analyzer to check the connector, however if you used an Ohm or Multimeter you are probably good to go.

Troubleshooting

Cable Strip Reference Guide

Use the following guide to prepare coax cable to the correct "approximate" lengths:

Thanks for visiting, and happy soldering! 73, W5SWL