I have a selection of PCB header strips, in 0.10" and 0.05" and single and dual rows.
The 0.05" header pins align with the connector pins, so a header might form the basis of a suitable connector. Two single-row headers glued together have pins that are too wide, but a double row is too narrow.
Start with the double row header.
![](https://cdn.hackaday.io/images/4529641668218738247.jpg)
Now the pins are too narrowly placed to mate with the connector pins, but if we bend the pins out just slightly it might work.
After some experimentation, I found that a thin piece of brass and a thin piece of plastic would fit between both rows of headers. Then a thicker piece can be pressed between these two, and the header pins gently bent outward.
Shown below is the brass (yellow), thin plastic (black) and a thicker piece of aluminum pressed between them. The aluminum piece is too thick to go between the pins, so pressing down on it causes the pins to splay outward.
![](https://cdn.hackaday.io/images/1001668219038180.jpg)
And... that works. With the leads slightly splayed, the header fits into the connector slot and the pins make contact with the header pins.
![](https://cdn.hackaday.io/images/5538371668219214549.jpg)
![](https://cdn.hackaday.io/images/9381111668219288769.jpg)
Testing a few of the pins WRT the header shows good contact everywhere.
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