USB CHARGING cable for Garmin Fenix (5-7) / Forerunner / Vivoactive / Approach (and more models with the same USB-Connection)

How to charge a Garmin Fenix (5) without charging cable? DIY, building your own cable.

Designed with FreeCAD, moddels available.

To charge the watch, you can use the two outer connections for charging, regardless of polarity (works in both directions). It would be possible to hold the wires (voltage/ground) directly to the pins. However, the main problem is to keep the distance between the pins and maintain contact.

Parts list:

• 2.54mm Dupont Connector, 3 pin female, crimping tool
• Single Row Male 2.54 Breakable Pin, 3 pins
• USB-cable, a  charging cable with two wires is enough

Printing

Print both the files "Garmin_Fenix5_USB-ConnectingPad_V0" and the assembly helper "Garmin_Fenix5_USB-ConnectingPad_AssemblyHelper_V0".

Nozzle 0.2 mm, PETG, layer height 0.1 mm or less, maybe use variable layer height. Support is necessary.
I printed it with a Bambulab X1C and Elegoo PETG Rapid on Bambu Engineering plate.
 

Assembly

Prepare the cable. Cut the cable, crimp the wires and assemble the Dupont connector. 

Pinch off a 3-pole pin header, pull out the middle pin.

Put the assembly helper into the pocket of the connecting side at the printed part. Turn ist around and push in the pins WITH CARE (be aware of bending the pins). Maybe it's easier with the spacers. In case it's too hard, think about warming the pin with a soldering iron.

Pull out the spacers and push out the assembly helper.

Push the assembled connector into the pocket of the connector on the watch. Pull it out again and slightly push the pins in a little bit (~ 1 mm).

Connect the prepared USB-cable, push the connector with usb-cable into the connector on the watch, charge ;-)

If the pins are too losse, try to fix the pins with glue (cyanoacrylate adhesive), be careful not to insulate the pins with glue. Do this AFTER slightly pushing in the pins.

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