Process of making a jack-type electrical connector

A process of making a jack-type electrical connector comprising the steps of:

• molding a plurality of plastic housings connected together a predetermined distance by plastic connecting segments, each housing having:
• a main plug receiving opening and cavity;
• a recess in one outer surface of each housing adjacent said opening that includes a pair of notches, each notch located opposite the other notch;
• a plurality of passages between the cavity and another surface of the housing opposite said surface with the recess;
• and a plurality of grooves on the outside surface of the housing arranged in a predetermined manner between said passages and said recess;
• stamping from a single sheet of metal a plurality of electrical conductors arranged into a plurality of groups of electrical conductors in the same spaced relationship as the passages in respective housings;
• said conductors including a plurality of first metal end segments and a second metal end segment, each of said first metal end segments located at one end of a respective group of electrical conductors, said second metal end segment located at the other end of said conductors to connect each group of conductors together;
• forming one end portion of each group of conductors adjacent said second metal end segment into a predetermined configuration;
• molding to said portion of each group of conductors formed into the predetermined configuration a respective plastic member having a pair of tabs adapted to snap into the pair of notches in the recess of a respective housing;
• removing the plurality of first metal end segments from said plurality of electrical conductors to provide a plurality of free ends;
• placing the free ends of each group of electrical conductors into the passages in respective housings;
• forming each group of electrical conductors into the grooves in respective housings;
• placing the tabs of each plastic member into the notches of a respective housing recess to retain each electrical conductor in a groove between the passages and the plastic member mounted in the housing recess;
• and
• removing the second metal segment from said groups of electrical conductors.