[ayeckley]

A word of caution when using the Delphi connectors: you probably want to order more housings than you think you might otherwise need, since they do not appear to be very tolerant of pin extraction.

In other words, things work as expected the first time a set of contacts is installed into the housing; the contacts are retained securely. If you later try to remove those contacts - at least in our experience - it will damage the plastic housing to the point that any new contacts that are installed won't be retained nearly as securely as the original set. We're clearly damaging the housing when we extract the contacts. We don't have access to any kind of "manufacturer certified" extraction tool, so we use a jeweler's screwdriver to push in the retaining tang on the contact - it's just that something in the housing appears to get damaged along the way and it's not obvious what that might be (need to get it under a microscope to tell for sure).

Our primary countermeasure is to always use a "fresh" housing on the final configuration of the robot. We also apply hot glue to the housing to help retain the contacts if we're forced to re-use an old housing.

Anyhow - hopefully that info is useful to someone.