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Old 7th September 2012, 11:01 AM   #1
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Default 5.5mm barrel jack & plug

Hi guys and gals,

I'm working on a power amp design to be fed by one of those standard laptop supplies.
I noticed that those supplies have connectors specced like outer diameter 5.5mm and inner diameter 2.5mm. The corresponding panel mount jack then should have a hole with inner dia 5.5mm and center pin 2.5mm. Or so I thought.

But the panel mount jacks I find have an inner pin like 2.35mm diameter, I can't find anything with 2.5mm inner pin.

Is that normal, is there a smaller dia pin to improve mating and contact (the inner pin is normally slotted and the two halves spread out a bit)?
So, am I OK with a 2.35mm pin for a 2.5mm connector?

jan didden
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Old 7th September 2012, 11:11 AM   #2
AndrewT is offline AndrewT  Scotland
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Join Date: Jul 2004
Location: Scottish Borders
I can't get in deep enough to measure the PIN diameter of my 5.5mm power socket.

The 5.5mm power plug takes a 2mm drill and is a very slack fit.
I don't have a 2.35mm drill to check that fit.
A 2.5mm drill will not fit.
regards Andrew T.
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Old 7th September 2012, 10:43 PM   #3
Enzo is offline Enzo  United States
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Join Date: Sep 2004
Location: Lansing, Michigan
There needs to be at least a small amount of slack space or the thing won;t always fit. The side contact in the jack is springy and pushed the barrel to the side so one side of the pin will be pressed against the inner wall of the hole.
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