I went through this a few years ago and put a page together to explain what I did. The suppliers might not be up to date but the info is still valid. http://ted.drain.googlepages.com/cables_index.html
I had a site up awhile ago that detailed how I build Canare/Belden cables without buying the expensive Canare dies. I changed providers awhile ago and never bothered to get it back up. But - thanks to Google's free hosting, here it is: http://ted.drain.googlepages.com/cables_index.html...
Here's a write up I did awhile back w/ some instructions for making an S-Video cable. Takes some patience but it isn't too difficult. http://www.geocities.com/teddrain/diy_cables/index.html
Woops - guess I didn't read that very well :) Here's the crimper that I have: RCA/BNC/F Crimper The F, RCA, and BNC connectors for that system are listed at the bottom of the page.
I built all of my cables w/ Canare connectors and Canare and Belden cable using the cheaper Paladin tools. It takes a little more time to do correctly but you can get the tools for around $100. You can see the details (including where I purchased everything) at...
Another vote for 3/4" holes. That's what I used through 2 sheets of 1/2" plywood glued together. It was a snug but not too tight to get together. I built a small jig for the drill press to align each hole and everything went together great. If I had it to all over again, I would have clamped...
The easiest way is just to try it. I think I used up about 6" of wire getting my radio shack stripper to the right specs. At $7 per stripper, I just get one for each cable type I'm building.
It will depend completely on the builder and how flexible they want to be. Some builders will be very flexible and some won't budge an inch. We're moving in to a semi-custom home in 2 weeks. We didn't want a full home theater room but I do like it quiet in the house so I wanted all the...
Chip, I was under the impression that the black oxide finish was corrosion resistant. At least that's what the description in the McMaster-Carr catalog says (page 2944 on their web site http://www.mcmaster.com/ ) I really wanted black for my flexy but wasn't sure what the black-oxide rods...
I'd say go w/ the 3/4" rod. It's incredibly strong and, IMHO, it looks better than the smaller rods. Here's a shot of mine: Cherry and marble flexy I bought all my hardware at McMaster-Carr They have an enormous selection and good prices. I thought about using all stainless hardware but...
McMaster-Carr is definitely the place to shop! http://www.mcmaster.com/ Try searching on 'threaded rod'. Click the first link found. You can then refine the search by clicking on the various attributes. I used 'english', '3/4" #10', 'zinc-plated steel'. For nuts, search on 'hex nut'...
You can also check out my site at: http://home.earthlink.net/~teddrain/diy_cables/ It describes how to make Canare/Belden cables without buying the Canare crimping and stripping tools. It also has links to where you can by cables by the foot and connectors.