Emon
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What you want is epoxy casting resin, it's made specifically for hobby die casting. You pour the epoxy resin into a mold and add a small amount of hardening catalyst. It's not a 1:1 ratio like adhesives, probably because it's in the natural form. I.e. the catalyst is not diluted to make a convenient 1:1 ratio.
Here's what you'd want your mold setup to look like:
You want to make sure you completely and fully cover the plugs with the clay. The optimal clay would be a soft, lower viscosity (not like the really liquidy stuff you have to bake) clay that can harden without baking, or at least come close. You want to pull the plug out by the cord. Don't worry that you won't mold to the taper on the plug, an accurate fit with the plugs is most important. Epoxy casting resin isn't an adhesive, but I'm not sure how it well it sticks. I'd assume it's mostly for low level DIYers that buy molds and cast many parts themsleves, in which case the molds are made or coated with a material epoxy won't stick to, like Teflon. Since we're talking clay here, and clay means semi pourous...I'd suggest that once the mold is hard, pour olive oil in. Let it "soak" in a little, then pour it out. Then rinse it out with plain water. You should get a thin oily skin that the epoxy won't stick well to. I'm thinking thick oil layers or talc will just slurry and mix with the epoxy. The resin is thin like water until you add the hardener. Worse case scenario, the epoxy sticks a little and you have to bust off the clay and sand/scrap off any clay that adhered to the plastic.
After the inside of the clay mold has been oiled up, you'll want to solder your wires to your plugs and insert them down into the mold. Fill it all the way up. You'll get a big ugly square which you can then carve and shape into a nice taper like the actual plugs. You can even add a large peice of heatshrink as a strain relief.
The only thing better I can think of would be vacuum forming a mold. Home vacuum formers aren't hard to make but might be a waste of time. Might look a little nicer in the end depending on your level of skill and craftsmanship when shaping the plug if you used clay. Vacuum forming probably wouldn't get the necessary detail for the plug's snap, however.
The pins you can probably get from Digi-Key, Mouser or another electronics supplier. Just measure the pins and get whatever you can that's closest, it's probably a standard. Would be a good idea to order several sizes near your measurements however, to be safe.
Here's what you'd want your mold setup to look like:
You want to make sure you completely and fully cover the plugs with the clay. The optimal clay would be a soft, lower viscosity (not like the really liquidy stuff you have to bake) clay that can harden without baking, or at least come close. You want to pull the plug out by the cord. Don't worry that you won't mold to the taper on the plug, an accurate fit with the plugs is most important. Epoxy casting resin isn't an adhesive, but I'm not sure how it well it sticks. I'd assume it's mostly for low level DIYers that buy molds and cast many parts themsleves, in which case the molds are made or coated with a material epoxy won't stick to, like Teflon. Since we're talking clay here, and clay means semi pourous...I'd suggest that once the mold is hard, pour olive oil in. Let it "soak" in a little, then pour it out. Then rinse it out with plain water. You should get a thin oily skin that the epoxy won't stick well to. I'm thinking thick oil layers or talc will just slurry and mix with the epoxy. The resin is thin like water until you add the hardener. Worse case scenario, the epoxy sticks a little and you have to bust off the clay and sand/scrap off any clay that adhered to the plastic.
After the inside of the clay mold has been oiled up, you'll want to solder your wires to your plugs and insert them down into the mold. Fill it all the way up. You'll get a big ugly square which you can then carve and shape into a nice taper like the actual plugs. You can even add a large peice of heatshrink as a strain relief.
The only thing better I can think of would be vacuum forming a mold. Home vacuum formers aren't hard to make but might be a waste of time. Might look a little nicer in the end depending on your level of skill and craftsmanship when shaping the plug if you used clay. Vacuum forming probably wouldn't get the necessary detail for the plug's snap, however.
The pins you can probably get from Digi-Key, Mouser or another electronics supplier. Just measure the pins and get whatever you can that's closest, it's probably a standard. Would be a good idea to order several sizes near your measurements however, to be safe.
