How to Make your own Network Cables

CAT5 cable contains four pairs of copper wire. CAT5 supports Fast Ethernet networks.  As with all other types of twisted pair CAT5 cable runs are limited to a maximum recommended run rate of 100m (328 feet).

Although CAT5 cable contains four pairs of copper wire, Fast Ethernet communications only utilize two pairs. The newer CAT5e standard uses all of the wires.  

Twisted pair cable like CAT5 comes in two main varieties, solid and stranded. Solid CAT5 cable supports longer leads and works best in long, straight runs.  Stranded cables are better suited to smaller patch cables because they are more pliable and can be worked into tight areas.

The anatomy of this cable is important:  It is called twisted pair cable because the wires twist around each all the way through the jacket.  If they become unraveled, the lines will be out of spec and susceptible to cross talk.   

First, strip the jacket covering about 1/2" from the ends and untwist the wires.  Arrange them according to the color pattern on either side and flatten the wires between thumb and forefinger.  Next, snip the ends so that the wires are exactly the same length--this is important.  With the clip of the head facing away from you, slide the wire into the head, making sure that each color goes into its respective position.  The end of the jacket must also fit into the end of the head.  Once you are sure the wires are in the proper position and all the way in, put the head into the crimping tool and give it a firm squeeze--do not over tighten.  You should hear the crisp snap of the plastic wedge gripping the end of the jacket and the copper pins biting into each of the wires.