Connector devices having a flushed and zero gap finish and methods of manufacture

A method of making a connector, the method comprising:

• providing a front shield shell and a rear shield having a reduced profile relative to the front shield shell, the front shield shell and rear shield shell being separate components and the rear shield having a plurality of deflectable tabs at a distal end thereof;
• positioning the rear shield shell partly within the front shield so that a proximal portion of the rear shield shell extends outside of the front shield shell and the plurality of deflectable tabs engage the front shield shell;
• and
• coupling the front shield shell and the rear shield shell to form a shield shell having a distal portion and a stepped-down proximal portion, the distal portion corresponding to the front shield shell and the stepped-down proximal portion corresponding to the proximal portion of the rear shield shell extending outside the front shield shell,
• wherein the front and rear shield shell are dimensioned so that when distally advancing a boot having a distal cavity to fittingly receive the stepped-down proximal portion of the shield shell within the distal cavity, the outer surface of the boot is flush with an outer surface of the distal portion of the shield shell.

A USB cable connector comprising:

• a connector end having a plurality of contacts positioned within a first shield shell housing;
• a cable having a plurality of wires;
• and
• a connector body coupled inline between the cable and the connector end, the connector body having a second shield shell housing having a reduced profile relative the first shield shell housing and a plurality of bonding pads positioned therein, each of the plurality of bonding pads electrically coupled to one of the plurality of contacts and one of the wires, the second shield shell and first shield shell being separate components that are coupled together, wherein the second shield shell has a plurality of deflectable tabs at a distal end thereof;
• wherein the first shield shell of the connector end has an outer surface that is flush with an outer surface of the connector body along substantially the entire periphery of the connector when an external boot member is disposed over the second shield shell.