I’ve been making connectors out of headers.
2) no special tools
3) any number of conductors
1) not robust
I tabled this with my friends and this is what came back.
I use pre-crimped wires from pololu.comYou could take wire #1850(black m-f), cut it in half, and insert the ends into housing #1902. They have a full assortment of colors. I keep a full set of them so I can make cables as I need them.
Pin headers are not designed to be free hanging. They are engineered
to be soldered onto PCBs. Your big solder blobs will definitely heat
and damage the plastic bases.
Try using molex connectors –
Digikey sells them in numerous sizes and configurations. You can
usually bypass the expensive crimping tool with skill and hand tools.
Much better 4 pin version:
Okay, this is what I got:
I got a great clear answer back from polulu:
In order to perform wire to wire connections using the crimp connectors, you will need both male and female crimp pins (item numbers 1931 and 1930). Our crimp connector housings are compatible with both the male and female crimp pins, and you can use them to make various sized custom connectors:
If you would like to try these connections without attempting the crimping yourself, we have a selection of wires with the crimp pins already attached:
If you determine that the crimp pins will work for what you are doing, you might consider using one of our compatible crimping tools, for example:
920 Pilot Rd.
Las Vegas, NV 89119