ken inscribed thus:

Everyone,

After reading your comments did some searching on Molex site and
found this "The pins come in either the standard (2.13mm) .084" or
(2.096mm) .0825" diameter."

I don't think 1.5 thou is going to make a lot of difference to a
connector with 20+ thou of compliance.

Maybe the problem is the HDs with poor electrical contacts have the
smaller pins?

If you look closely the male pin has a taper along its length.

The issue is that the female part gets expanded with use. Simple
misalignment of the pins as they are mated and detached. They do
float slightly but nowhere near enough to compensate.

If you remove a female pin from the housing and try it on a male one
you will see what I mean.

Here is the link for the Molex 8981 power connectors

http://www.molex.com/cgi-bin/bv/molex/jsp/family/intro.
@@@@&BV_ EngineID
=cccgaddmdfjmelmcflgcehedffgdfmk.0&oid=-8470&channel=Products
&familyOID=-8470&frellink=Introduction&chanName=family&
pageTitle=Disk%20Drive%20Power%20Connector%20%20Ov erview

Thanks again everyone for your suggestions!

Ken

--
Best Regards:
Baron.