how to make an ethernet cat5e cat6 cable

At DlayCable, we’re not just a leading manufacturer of high-performance network cabling; we’re experts dedicated to empowering our partners and customers. We believe that understanding the fundamentals of network infrastructure is key to building robust and reliable systems. While we offer a vast range of pre-terminated patch cables for convenience and certified performance, knowing how to create a custom-length Ethernet cable is an invaluable skill for any IT professional, network installer, or dedicated DIYer.

dlaycable will walk you through the entire process, from selecting the right materials to testing your finished cable, ensuring you can create professional-grade connections tailored precisely to your needs.

1. Before You Begin: The Importance of Quality Components

The performance of your final cable is only as good as its weakest component. As manufacturers, we can’t stress this enough. Using subpar materials will lead to signal loss, slow speeds, and connection drops, regardless of how perfect your technique is.

• Bulk Cable: Choose a cable that matches your needs. For most modern networks, Cat6 is the recommended standard for new installations, offering better performance and future-proofing over Cat5e. Critically, always opt for 100% pure solid copper conductors. Avoid Copper Clad Aluminum (CCA) cables, which are brittle, perform poorly, and do not comply with TIA/EIA standards.
• RJ45 Connectors (Plugs): These aren’t all the same. Ensure your connectors are rated for your cable type (Cat5e or Cat6). Cat6 connectors have staggered internal channels to reduce crosstalk between the wires, which is essential for achieving higher speeds. Using a Cat5e plug on a Cat6 cable is a common point of failure.

2. Essential Tools & Materials Checklist

Gathering everything you need beforehand makes the process smooth and efficient.

• Bulk Ethernet Cable: A box of DlayCable Cat6 Pure Copper Riser (CMR) or Plenum (CMP) cable.
• RJ45 Connectors: High-quality Cat6-rated plugs. We recommend pass-through connectors for beginners, as they simplify the process of verifying the wire order.
• Crimping Tool: A quality RJ45 crimper is a long-term investment. Many models also include a built-in cable cutter and stripper. A pass-through specific crimper will also trim the excess wires automatically.
• Cable Stripper: While some crimpers have one, a dedicated jacket stripper provides a more consistent and safer cut without nicking the inner conductors.
• Flush Cutters or Scissors: For a clean, straight cut of the conductors.
• Ethernet Cable Tester: This is not optional. A simple continuity tester is affordable and will save you immense time and frustration by immediately verifying your connections are correct.

3. Understanding Wiring Standards: T568A vs. T568B

There are two recognized standards for wiring Ethernet cables: T568A and T568B. Functionally, they are the same. The only difference is the position of the orange and green pairs.

The golden rule is to pick one standard and use it consistently throughout your entire network project. For new commercial and residential networks in North America, T568B is the dominant standard. We will use T568B for this guide.

To create a standard ‘straight-through’ cable (used for connecting a computer to a switch, router, or wall plate), you will wire both ends of the cable using the same standard.

4. Step-by-Step Guide to Making Your Ethernet Cable

With your tools and materials ready, let’s build your cable. Take your time and focus on precision.

1. Step 1: Strip the Cable Jacket

   Using your cable stripper, carefully score and remove about 1-1.5 inches (3-4 cm) of the outer cable jacket. The goal is to cut only the jacket without nicking the twisted pairs inside. Once scored, the jacket should pull off easily.

2. Step 2: Prepare the Wires

   You will see four twisted pairs of wires and likely a plastic spline (in Cat6 cable) and a rip cord. Cut the spline and rip cord flush with the jacket. Then, carefully untwist each pair and straighten them out as much as possible. This is a critical step for getting the wires to lay flat later.

3. Step 3: Arrange the Wires (T568B)

   This is the most important step. Pinching the wires near the jacket, arrange them from left to right in the T568B order: White/Orange, Orange, White/Green, Blue, White/Blue, Green, White/Brown, Brown. Keep them flat and parallel, ensuring none are crossed over.

4. Step 4: Trim the Wires

   Once you are 100% confident in the order, pinch the flattened wires tightly. Using your flush cutters or the blade on your crimper, make a single, clean, straight cut across all eight wires, leaving about 0.5 inches (1.25 cm) exposed from the jacket.

5. Step 5: Insert Wires into the RJ45 Connector

   Hold the RJ45 connector with the tab facing down. Carefully slide the aligned wires into the connector. Push firmly but gently until you can see the copper end of each wire at the tip of the connector (this is where pass-through plugs are a huge help). The cable jacket should go inside the connector by about a quarter-inch to be properly secured by the crimp.

   Pro Tip: Double-check the wire order one last time through the transparent plug before crimping.

6. Step 6: Crimp the Connector

   Insert the connector into the appropriate slot on your crimping tool. Squeeze the handle firmly and decisively. You should hear a ‘click’. This action does two things: it pushes the gold-plated pins into the wires to make contact, and it secures the cable jacket to the plug for strain relief. If using a pass-through crimper, it will also neatly trim the excess wires.

7. Step 7: Repeat for the Other End

   Now, repeat steps 1-6 on the other end of the cable, ensuring you use the exact same T568B wiring standard.

5. The Final Step: Testing Your Cable for Perfection

Do not skip this step! A cable tester will save you from future headaches. Plug each end of your newly made cable into the tester. A good tester will have a series of lights (1 through 8 and Ground). As it tests, the lights should illuminate in sequence on both the main unit and the remote unit. If they all light up green in a 1-to-1 order, your cable is a success!

6. Common Mistakes & Troubleshooting Tips

• No lights on tester: A wire is not making contact, or you have a short. Re-check your crimp and ensure the wires were pushed all the way in. You may need to cut the end off and start again.
• Lights are out of order (a “cross”): You mixed up the wire order. This is the most common mistake. Cut the end off and carefully re-do the T568B alignment.
• A single light doesn’t illuminate: The specific wire is not making contact. The pin may not have been pushed down far enough during the crimp, or the wire is broken. Re-terminate the end.
• Slow connection speeds: This can be caused by using low-quality components (CCA cable, wrong plugs), untwisting the wires too far back from the plug (violating the 0.5-inch rule), or a bad crimp.

7. Your Network, Built with DlayCable Quality

Congratulations! You’ve successfully created a custom, high-performance Ethernet cable. This skill gives you complete control over your network installation, ensuring clean cable management and a professional finish.

By starting with superior components like DlayCable’s 100% Pure Copper bulk cable and the right tools, you guarantee that your hard work results in a reliable, high-speed connection that will last for years. For your next project, explore our full range of bulk cabling, connectors, and tools to build your network with the quality it deserves.