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2024-02-19: Don't use DC barrel jacks in your projects

I needed to redo the connection cable for my TS-100 soldering iron, which needs 24V via a 5.5mm DC barrel jack. After ordering a cheap set from amazon I realized two things:
  1. Most of the jacks without a pre-attached cable on Amazon are the same "RUNCCI-YUN" product. They are all extremely low-quality.
  2. There are 2.5mm and 2.2mm jacks. The TS-100 needs 2.5mm and I got 2.2mm.
A good alternative are XT60 or XT30, which slip less and can handle high amperage. While they lack strain relief for the cable, this can easily be compensated with shrink tube or tape. There are also XT60 plugs for case-mount, in case you need an alternative to case-mount barrel jacks. The latter often have bad cast threads on them, which makes installing them frustrating. If you can't avoid barrel jacks it'S worthwhile to buy them from digikey, Conrad, or other places where you can get high-quality electronics. Amazon seems to be beyond the tipping point, where the convenience is overshadowed by the sheer volume of bad parts.