Coring system and method for manufacturing a one-piece die cast electrical connector body

A method of producing a die cast flash free one-piece connector body for securing electrical cables to a panel including the steps of:

• providing a first core including a base portion, a tubular nose portion extending from said base portion, an end on said nose portion, a narrow end portion formed by two grooves on opposing sides of said tubular nose portion, and a shoulder at the end of each of said grooves;
• providing a second core including a base portion, two parallel and generally tubular fingers extending from said base portion to an end, and an open channel between said fingers;
• joining first core and said second core into joined cores by extending said narrow end portion of said first core into said channel on said second core until said end of said fingers of said second core engage said shoulders on said first core;
• providing a mold including an elongated mold cavity having opposing ends therein;
• placing said joined cores into said elongated mold cavity in such a manner that said joined cores are longitudinally aligned in said cavity and said base portions are at said opposing ends of said elongated cavity;
• closing said mold;
• and
• admitting molding material into said cavity of said mold to form said one-piece connector body.