Postby MKB » 16 Feb 2009, 16:31
Here's a few tips:
1) Be careful with the heat as many 1/4" plugs have plastic insulators (if there is a black ring between the tip and sleeve on your plug, you have a plastic insulator). If you get the plastic too hot, the parts in the plug can loosen and you'll get intermittent connections. I normally throw away all plastic insulator plugs and replace them with Switchcraft plugs with bakelite (brown) insulators.
2) If the parts wobble on the plug, throw the plug away. Even good plugs like Switchcraft can loosen over time and cause problems.
3) It is very possible to have bad cable as well as bad plugs. Probably half of the bad cables I've had over the years had good plugs but bad wire. The bad spot in the wire is usually very hard to find, it's best to throw the cable away.
I make all my own cables now from Switchcraft ends, adhesive heat shrink and Belden 8412 cable. These cables are basically indestructible, I haven't had a single one break or go bad in 10 years of moderately hard gigging.