Electronics > Beginners

Cable that fits Barrel Jacket plug?

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mariush:
Why do you keep looking around in various places and guess?

Just go at distributors of electronic components and electronic related things and get some actual data.
For example, Digikey has a VERY GOOD filtering mechanism.

Go to barrel jack connectors, filter by the ones with 5.5mm OD (outer diameter) and 2.1 / 2.5 mm ID (inner diameter):

2.1/5.5 (28 plugs) : https://www.digikey.com/products/en/connectors-interconnects/barrel-power-connectors/435?k=&pkeyword=&sv=0&pv28=387800&sf=1&FV=-8%7C435%2C1954%7C124090&quantity=&ColumnSort=0&page=1&pageSize=25

2.5/5.5 (26 plugs) : https://www.digikey.com/products/en/connectors-interconnects/barrel-power-connectors/435?k=&pkeyword=&sv=0&pv1952=9405&sf=0&FV=28%7C387800%2C1954%7C130727%2C-8%7C435&quantity=&ColumnSort=0&page=1&pageSize=25

All you have to do is open the datasheet for random connectors from the results (pretty much every result has datasheet) and look at the schematic to get the diameter.
Here's a random example... you see it says 4mm +/- 0.5mm (0.157") : https://www.cuidevices.com/product/resource/pp3-002b.pdf
 
Now you can look at cables ... there's almost 21K single wire cables on Digikey: https://www.digikey.com/products/en/cables-wires/single-conductor-cables-hook-up-wire/474

You can filter by gauge.

Here's AWG18 : https://www.digikey.com/short/p194qj

You can look at "Jacket (insulation) diameter", that will tell you the overall diameter of the cable.  "Jacket (insulation) thickness" will tell you the thickness of the insulation.
You can see you have wires as thin as 1.3mm and as thick as 6.73mm.
You can then further filter by insulation material and see silicone cables how thick they are : https://www.digikey.com/short/p194jm   - as you can see they're anywhere from 1.98mm to 6.12mm

Either way, assume the majority of awg18 cable is gonna be under 2.3mm but it's unlikely they're gonna be 2mm or less... as the diameter of the hole is 4mm, you're not gonna fit two in the connector.


Also, you may be better off buying pre-made cables.
Here's 2.1/5.5: https://www.digikey.com/products/en/cable-assemblies/barrel-power-cables/464?FV=28%7C125172%2C-8%7C464&quantity=50&ColumnSort=1000011&page=1&pageSize=25
Here's 2.5/5.5: https://www.digikey.com/products/en/cable-assemblies/barrel-power-cables/464?k=&pkeyword=&sv=0&pv28=131840&sf=0&FV=-8%7C464&quantity=50&ColumnSort=1000011&page=1&pageSize=25

admiralk:

--- Quote from: mariush on December 13, 2019, 08:14:26 pm ---...
All you have to do is open the datasheet for random connectors from the results (pretty much every result has datasheet) and look at the schematic to get the diameter.
Here's a random example... you see it says 4mm +/- 0.5mm (0.157") : https://www.cuidevices.com/product/resource/pp3-002b.pdf
 ...

--- End quote ---

And here is a random one that says 6.6mm. http://www.switchcraft.com/Documents/NPB_583_-_sealed_power_plug_&_jack100315_edit7_30_2012.pdf
Here is one that is adjustable. https://media.digikey.com/pdf/Data%20Sheets/Tensility/55-00096_50_51_Assem_Instr.pdf

Since he already has the wire, it might be a better idea to find a plug that will accommodate the wire. What is really fun is matching multiple plug types; RCA, Mini XLR, etc. with the same wire. 

tooki:

--- Quote from: ElectricPower on December 13, 2019, 06:23:19 pm ---I have seen some youtube videos and it looks like 18awg silicone cable is 2.2mm thick. That means 4.4mm for two wires. 16 awg is 3mm, and i espect 6mm total going to be tight yes...

--- End quote ---
There isn’t one thickness per gauge. It varies by cable type. Silicone wire varies wildly in overall thickness even within a given gauge. For example, Pomona (Fluke) makes 18ga silicone test lead wire which is 3.6mm thick.

You really need to just a) stop operating on assumptions and guesses, and b) do as mariush said and start doing your own research on actual parts you want to use.

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