Power for test Xbox

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On my bench I have a test mains power input for testing Xboxes along with a test AV cable connected to a TV.

Today I wired an Xbox power safety device into the mix. There’s a tear down of this highly over-engineered device on the EEVBlog video: EEVblog #1164 – Xbox Engineering Baptism Of Fire.

Microsoft made this to cover for defective mains power connector in their earliest hardware versions. The problem was that the socket was only soldered into the board and didn’t have sufficient mechanical support. The solder joints could wiggle around, become loose, get hot, and then let go the magic smoke.

Anyway this device is both a fuse and an earth leakage detector, so very happy to have it as part of my setup.

Brass vs. Phosphor Bronze

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Today I learned about Brass vs. Phosphor Bronze. There’s more to know. My guess is that Phosphor Bronze is probably best for Contact, Commercial MATE-N-LOK, Socket, Crimp, 18 AWG, Tin Plated Contacts.

Update: actually looks like tin plated brass is more common/standard/cheaper? than phosphor bronze. I think it’s a technical detail that probably doesn’t matter much. Some products just say “copper alloy”, and they’re both copper alloys.

Picking a 16-channel external power connection

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So I’m planning to put an Xbox power supply,

in a box,

I wasn’t sure exactly which box, so I got four, hoping one would work.
The sockets and pinouts vary,

So I will need to make three different types of cables, one for each version range: v1.0-v1.1, v1.2-v1.5, v1.6. But those vary only on the “motherboard side”, the connector that connects to a power supply in a box can be anything, and I can pick it. By my count the maximum cable requirement is 16 cables. So I’m looking for a recommendation for what power connector to install the on the box. Ideally something I can bolt into the box that can handle a couple of amps of DC and into which I can plug my custom cable. Craig? :)
Update: from here maximum observed current 8.6A. I would like to use D Sub Connector Housing, 25 Ways, D Sub, 3, AMPLIMITE HDP-20, Receptacle, Steel Body but I’m not sure if they’re rated high enough for the current.