Creating a spiral USB cable requires precision in wiring, heating, and assembly. Follow this guide to achieve a professional, durable result.
1. Tools and Materials Needed
Essential Tools
Heat gun (hairdryer is insufficient)
Soldering iron + solder wire
Diagonal cutters/scissors/utility knife
Wire stripper (optional)
Small screwdriver
Cable and Connectors
USB Type-A/C/Micro USB male connectors
4-pin aviation connector (e.g., GX-16)
28AWG 4-core shielded cable (OD ≤3mm)
Paracord or braided sleeve (4mm)
Auxiliary Materials
Heat-resistant electrical tape
PE triple-wall heat shrink tubing (ID 12.7mm)
Heat-resistant cylindrical rod (OD ~16mm, e.g., wooden dowel/steel pipe)
2. Step-by-Step Guide
Step 1: Prepare the Cable
Cut to length: Trim the shielded cable to desired lengths (e.g., 1.2m for PC connection, 3m for desk extension).
Add protection: Slide paracord or braided sleeve onto the cable. Seal one end with heat (lighter) to close the loop, then pull out the inner nylon string.
Step 2: Process Connectors
Disassemble aviation connector: Remove the outer shell of the GX-16 connector, keeping the male/female pins.
Strip and tin wires: Use a wire stripper to expose the 4 copper cores at both ends. Pre-tin the wires with solder.
Slide on shells: Thread the USB connector shells and aviation connector shells onto the cable before soldering.
Step 3: Solder Connectors
Step 4: Test Functionality
Initial test: Connect USB Type-A to a 1A charger and plug into an old phone to verify power.
Troubleshooting: If no response, use a multimeter to check voltage (USB pins 1 & 4 should read 5V). Re-solder if needed.
Step 5: Shape the Spiral
Secure one end: Tape the USB Type-C end to the cylindrical rod using electrical tape.
Wind the cable: Coil the cable tightly in one direction, ensuring each loop touches the previous one.
Secure the other end: Tape the aviation connector end to the rod.
Heat-set the shape:
Step 6: Assemble the Shells
3. Key Tips and Precautions
Soldering Quality
Heat-Setting Temperature
Coiling Direction
USB Standards Compliance
4. Common Issues & Solutions
