[electroken]

We're making our own as well.

Housings: Molex 50-57-9003

Female contacts: Molex 16-02-1114 These are called "high force" contacts and should stay put while the robot is getting beat up.

I really don't like the formed male contacts. We've gone a different route and are making our own using the female contacts and soldering 0.025" header pins into them prior to crimping. It takes some time doing this with 0.016" solder under magnification, but were getting stronger, straighter pins. Make sure you're using the right crimper and pull-test every pin.

Just about any 22AWG wire will do. We're using very finely stranded stuff (about 100 strands) intended for high motion applications.