Global GSP-1600 Charger Cable Strain Relief

I needed to repair a Globalstar GSP-1600 satellite phone wall charger cable. In storage, the wire's insulation got brittle and cracked from just handling it. Replacing the wire also means replacing the strain reliefs on each end. The original strain reliefs are molded onto the wire, so you can't just take the wire out and put a new one in.

I couldn't find any strain reliefs for sale that looked like these, and/or matched the sizes of the housings, so I made these.

The original wire was two 24g conductors with a 4mm OD (outside diameter). I couldn't find a matching wire, so I used a wire with 20g conductors and 3.6mm OD. That's thicker wires inside, but a slightly smaller outside.

The strain reliefs on each end are different sizes, and have a different shape on the lip where it goes into the housings. So I modeled these to perfectly match the original shape and functionality. I wanted it to look like it was brand new after the repair. I think I did that.

If you do this, you need to be good with a soldering iron. There isn't a lot of room inside the housing on the phone end, so you can't leave any extra wire inside it.

There are 3 sets of files, two each. You only need a single pair of files, of whatever format you prefer. They're all generated from the same models.

Two Fusion 360 f3d exports, if you want to adjust it for your needs.
Two .3mf files. This is the newer better sharing format. Everyone should want this.
Two .stl files. We're supposed to retire .stl, but I know some of you will want it.

This is mostly parametric, so you can adjust a lot to make it work for other applications. Fusion does get a little confused when you make changes, so expect to need to extrude and reapply filets.

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