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DIY 4 wire Kelvin leads

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drummerdimitri:
I'd like to make the best leads to benefit from the 4 wire resistance measurement capability of my DMM6500 however, I need some pointers on how to make the best ones possible.

Firstly, what gauge silicone wire should they be? I need them to be between 1 and 1.5 m long.

I got these connectors which have separate connection points so I can wire two cables to each connector: https://www.aliexpress.com/item/32570109938.html?spm=a2g0s.12269583.0.0.9b9d33b004daba

Will be terminating them with gold plated banana plugs.

Anything else I should be concerned about?

Fire Doger:
"Best Leads" and aliexpress doesn't match.
These are not goldplated, they are gold painted.

Also I am sure there will be special wires for this purpose, depends how expensive you want to go.

MosherIV:
Hi

Yes, I got similar clamps
https://www.eevblog.com/forum/testgear/gold-plated-test-probes-any-good/25/

No, they are not the best but they work.
Do not worry, the gold plating is ok and so far has not flaked off.

You will actually limited by what will fit through the hole of the clamp housing.
I used a small uk based firm, they only supply 1 type of silicone test cable. So I just got that.
Everything they supply is good quality so I do not have to worry.

Think about strain relief. I put cable ties on my cables so the the cable tie is against the hole in the housing.

I used mine at work this week. Managed to measure 55 micro \$\Omega\$

drummerdimitri:
Initially, I soldered the cable to the bottom of the connector as it was intended since they had already placed a blob of solder there but then I realized I could solder way up right next to the points of contact which would help lower the lead's resistance by a bit and provide strain relief as the cables are held down tight by the springs :-+

All I need to do now is find a way to hold the cables in place. It's a shame there isnt any screwable piece of plastic  to keep it held in place.

I'd rather not use heat-shrink as it is not an elegant solution so maybe some hot-glue would do the trick?  :-//

Conrad Hoffman:
The nice thing about a 4-lead measurement is the leads don't matter much. Anything that pleases you is probably plenty good. I have a friend who makes them out of plastic clothes pins and copper tape!

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