Peltor to Ham Radio

 I have a Peltor Comtac 3 headset because reasons. I got it to use with my Motorola handhelds, primarily the XTS2500. For a long time I have wanted to adapt the two PTTs that came with it to work on other radios I own. Today I'm attempting to adapt it for a Yaesu FT-991A


These come with the 6 pin NATO connector, U-229, described on Cryptomuseum, here.

I need to remove this cable and add my own. I'll be adding two since few ham radios have audio in and out all on one connector. First I have to identify the function/color of each wire.


Pins on the connector are labeled A-F with corresponding functions below:
GNDA
SPKB
PTTC
MICD
EXPE
EXTF

I keep all pinouts I identify in a Google Sheet of pins, wire colors, and functions with pictures where able. I got the functions from that Cryptomuseum link above. 


Disassembly of the U-229 is simple with a wrench and some pliers. Then I add color of each wire to the spreadsheet near the appropriate letter.


Inside the PTT we now know which pad goes to each function. The pads with red and brown wires are nonstandard and not used by U.S. forces but can accept voltage in.

From a separate book of the google sheet I reference the Yaesu pinout. Someone, I forgot who, added the standard ethernet colors for each pin to the diagram in the manual and I grabbed this pic a while back. 


 A small bit of solder smoke later and we have new cables on the PCB. 

Unfortunately it doesn't work. It's always an impedance thing but I needed to start somewhere. I was hoping the PCB would already have the work done for me but obviously not. The audio out works but is weak, that's a minor impedance issue. The PTT function works and keys the radio. The microphone has no audio whatsoever, another impedance issue. I'll test it on my FT-897D just for fun and then maybe go down the Icom route. If none of those work I'll start building an amplifier circuit board to use the Peltor's microphone.

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