Tools you will or might need:
- crimper
- wire cutter
- wire stripper
- soldering iron
- heat shrink
- sleeving
- PSU tester
- heatgun
- molex pin removal tool
- molex pins
- molex connectors
This project was the Nvidia/Asus/OutoftheBoxMods charity project which was featured on the cover of CPU Magazine January 2010. Performance PCs custom-sleeved most of the PSU. I did a couple of the cables and also sleeved other cables such as lights. There are also pics of a PSU I sleeved for an Intel project included to show the full process.
I personally find it too time consuming to remove molex pins from PCI-E and ATX connectors. Instead I just buy replacements, cut off the old connector and then crimp on new pins and connectors. This is better in my opinion as you do not have to put more wear and tear on the parts that hold the pin in place.
First, cut off the old connector. Next, strip about half an inch of wire, then crimp on a new pin. I solder the connection just for good measure. Next, pull on the sleeving and two pieces of heatshrink (one piece on each end). Use the heatshrink gun on the pieces of heatshrink. Now place the molex pin into the correct spot on the molex connector. Use the molex connector you cut off as a reference.
Now insert the sleeved and pinned wire into the molex connector:
Looks nice:
Make sure you test it with a PSU tester (Performance PCs carries several)
Here are some of the cables Performance PCs and I sleeved for the charity project:
Pictures of the rig with sleeved cables: