F'in 4-H Electric 3 Project Fail

[HoosierBuddy]

So,

My 11 year-old is in 4H and this year is up to do the "Build an extension cord or a trouble light" project. For old time 4H dudes (like me) this is the same project we used to get as our second year 4H project (I still have my trouble light I built), but now it's done in year 3.

Anyhoo...we always get going on these things plenty early. This year, my son had his done a couple of months before they scheduled an informational meeting. That's when he found out that most people use a kit they buy from the 4H office to do the project.

I wasn't too worried when I heard that because I had gone over the specification sheet supplied with the project guidelines and together, we we went on partsexpress.com and bought 2 ends and wire that met or exceeded the specs.

The project was actually the easiest 4H project he's ever done. Compared to woodworking and even Electric 1 and 2 this one was a breeze. He put the thing together and I went through and checked every step of his work. He ended up with a very nice (nicer than you can buy in any store) 25-foot 14-gauge extension cord suitable for use in the shop (Oil and water resistant).

Fast forward to Saturday. He takes it in to get judged. No parents are allowed in during judging so I don't know what happened next exactly, but to judge it, it must be disassembled. The judge disassembled the male end and said "there is a loose wire" and gave him a red ribbon (this is the first time in 3 years he's gotten a red ribbon on any of his many 4H projects). Further he told my son to correct the loose wire so it could be reassembled and displayed. My son tried to tighten the wire and couldn't. Then the 4H leader tried. Then the judge tried. Finally they brought it to me and I saw right away that part of the clamping mechanism in the terminal was broken off and missing, and the wire can't be tightened.

Well, this just griped by *** to no end, because I know it was FINE when the project was assembled. Further, I never got a chance to talk to the judge about it. In fact, we were told by the 4H leader that it wasn't even allowed.

I'm convinced the judge broke it taking it apart. Specifically, I charge him here on GJ with trying to separate the housing from the rest of the plug BEFORE loosening the strain relief screws. He pulled on it hard enough to break one of the terminals. If we would have used the 4H kit, he probably would have been more familiar with the end, and this wouldn't of happened. The ends we used were MUCH more substantial than the ones supplied in the 4H kit. I'm sure (in my mind) that's what happened. But...my kid still gets a red ribbon.

I know this isn't a big deal, but it made me madder than I've been about anything in a long time. When they told me I was not allowed to speak to the judge, I just had to turn around and leave. If I would have stayed it would have gotten really ugly.

My son took it a lot better than I did. I'm proud of him.

Phil

 

[BigGMC]

What kind of plug end did you use? I can't fathom how you can break a terminal screw (or any of its associated parts) by removing the shell - even if the cord clamp isnt loosend first. Sounds like a defective part.
Perhaps your boy took it better because he realized its just a 4-H project..........

 

[HoosierBuddy]

Here's a picture of the "business end".

When they brought it to me, the screw was still there, but it was notably hard to turn (almost like a cross thread) and the mechanism does not tighten on the black wire at all. Not even a little bit.

I freely admit this bothers me more than it should, so we can probably leave any psychological profiling to a different forum.

I am very interested if anyone knows what went wrong here. I can tell you the following with certainty:

1. It was tight after my son assembled it. The screw was tight and the wire was solid.
2. The next time I saw it (after the judge, my son, and the 4H leader couldn't figure out how to fix it) the black wire was stuck in the terminal hole, but there was nothing clamped on it even with the screw all the way in.
3. I took the screw out completely, stuck the wire in and tried again and wire is not clamped even with the screw all the way in.

I'm not sure if the thing's broken or something has come apart in the terminal that keeps it from clamping anymore. I'm just assuming (maybe incorrectly) that it is actually broken. Maybe it's not broken. Maybe it just doesn't work anymore. I don't think the plug can be disassembled further without breaking it.

Phil

 

[justsam]

I have used those plug ends before, and I like them because they do a good job of keeping the wires away from each other and from my experience are quite robust. I think the plug end itself is stripped.

Kudos to you and your son for being engaged and spending time together! Believe me they grow up quick and just want the car keys from you!

If you are willing to accept some counsel from an old fart that didn't always get it right, remember your son is learning from you even when you are not aware you are being the teacher. There will be bumps and injustices in his livfe, as I am sure there have been in yours. He is learning from you how to react to them so deal with it in a manner you would like him to. This may be more of a lesson than the power cord!

 

[HoosierBuddy]

If you are willing to accept some counsel from an old fart that didn't always get it right, remember your son is learning from you even when you are not aware you are being the teacher. There will be bumps and injustices in his livfe, as I am sure there have been in yours. He is learning from you how to react to them so deal with it in a manner you would like him to. This may be more of a lesson than the power cord!

I see your point, Sam. I was going to write a long answer explaining why you are wrong...but about half way into it realized that you aren't.

The key here is, he did his absolute best. The project represented nothing but his maximum effort. If he would have gotten a red ribbon because he was careless or rushed or lazy, that would be unacceptable. Since he did the very best he could do, then it doesn't matter what ribbon he got.

I guess I have to say that, even though we live in a small, rural, area, and everyone in his club and about a thousand other people are going to see his project with his name and a big "fail" ribbon hanging on it at the 4H barn this week. He even went to a lot of extra trouble to make a nice display board to hang it on. That should give them a good place to hang that red ribbon that tells everyone he "Did not meet minimum standards."

Phil

 

[coolreed]

There are no mistakes in life,...there are only lessons.

There is a very good lesson here.

 

[BigGMC]

Here's a picture of the "business end".

When they brought it to me, the screw was still there, but it was notably hard to turn (almost like a cross thread) and the mechanism does not tighten on the black wire at all. Not even a little bit.

Hmmm, strange. Is the clamping plate still in the little cage.... mabe the defective terminal was missing it from the get go??
If the screw is still hard to turn even with no pressure on it, then its been cross threadded or threads weren't formed right when it was made.

Why would they display the project with its red tag?? Put it on display, fine, but to do it that way is stupid.

 

[rabidsquirrel]

He backed the screw out too far. The threads are damaged (can't think of the right word) so that you can't take the screw out without considerable effort. Once backed out that far, they rarely want to go back in.

 

[Outlander]

All projects have external forces that cannot be foreseen. Your son has just experienced this. Bravo to him for reacting well, and bravo to you for taking the time to walk him through the 4H program. I wish there was a program here when my kids were growing up.

 

[STINEY]

Having been a 4H judge myself (a mistake I will not make again, rest assured) I have to ask, what would have done when presented with a faulty project that the student was unable to fix when given the chance?

Keep in mind that a LOT of kids come to the judges with no idea of what their project is or how it works. There is a interview period with each kid, and every chance is given them to prove themselves...... should the deficient projects get the same award as the really really good ones with really engaged knowledgable kids?

Obviously I do not know you or your kid, and I honestly believe your angle on the situation. But the reason you don't get a chance to talk with the judge is that judges are hard to get to volunteer, especially when they know they are going to take a brow-beating from every parent whose kid didn't get the AAA++++ ribbon. As I said, I'll never do it again. The kids are awesome, all of them - the parents are another thing.

 

[phy6]

<googles to see what 4H is>