What is a fat od passthrough plug?

Fat OD Passthrough Plug: Heavy-Duty Field Connector

1. Core Function

Oversized Cable Fit: Built for thick cables (double-jacketed, armored, gel-filled) that won’t fit standard plugs.
Pass-Through Verification: Wires thread fully through the plug body—visible at the front—so you eyeball wire order before crimping.

2. Ruggedized Features

Industrial-Grade Shell: Thick nylon or PBT housing survives crushing impacts, oils, UV exposure.
Dual-Point Grip: Separate metal clamps bite cable jacket and internal Kevlar yarn—no pullouts under vibration.
Debris-Defying Contacts: Pins sit recessed behind a sealed barrier; mud/metal shavings can't short them.

3. Termination Workflow

Strip & Prep: Remove 40-50mm outer jacket; expose shielded pairs/Kevlar.
Feed Wires: Push conductors through plug until they protrude from the front.
Validate Sequence: Visually confirm T568A/B order through clear hood.
Crimp & Cut: Single tool action:
Compresses contacts onto wires
Locks strain clamps
Slices excess wires flush (built-in blade).

4. Where It Excels

Vibration Hell: Assembly lines, mining drills, railroad gear—where cables shake nonstop.
Filthy Environments: Foundries, food processing plants, wastewater sites needing IP68/IP69K seals.
Blind Panic Terminations: Low-light tunnel work or tight control cabinets—see wires instead of guessing.

5. Failure Traps

Ignoring Shield: Braid touching signal pins during feed-through = EMI chaos.
Kevlar Neglect: Forgetting to clamp strength member first → cable rips out later.
Burred Wires: Dull cutters leave copper spikes; pierces insulation, shorts PoE.

6. Tradeoffs & Limits

Port Depth Wars: Extra 3mm plug length jams shallow sockets (test fit first).
No Redos: Crimp = permanent; wrong wire order? Cut off and eat the cost.
Tool Headaches: Standard crimpers choke—requires beefy ratcheting tools.
Price Shock: Costs 8× standard RJ45 plugs; justify via reduced rework.

7. Vs. Standard Plugs