To begin the fabrication of the electrode set, first tie two pieces of PFA coated braided stainless steel wires together with a single knot. Insert an 18 gauge needle into a piece of corrugated cardboard. Position the knot six centimeters from the needles insertion end.
Then pull the electrode strands against the cardboard to tighten it around the needle. Carefully remove the needle to maintain the knot's integrity, and pull the knot tight two times to tighten it further. Next, tape the electrode taut against a piece of flat cardboard.
Ensure that the two connector end wires are together, and the insertion end wires are spread apart. With a scalpel, make precise nicks in the insulation, marking the ends where the insulation will be removed. Make a series of approximately six cuts at each marked location with two cuts each on top, at the sides, and underneath the wire.
Angle the scalpel blade to cut along the loosened insulation length wise, and use a pair of forceps to carefully remove it from the wire. Strip one millimeter insulation off the end of each wire at the connector end, and five millimeters off at the insertion end. Twist the wire segments at the insertion end together, and crimp the exposed ends in the shaft of a 0.5 inch 27 gauge needle.
Next, use a pair of straight forceps to carefully reinsert each soldered brass fitting back into the connector. Make sure that the wires of each electrode pair are adjacent and untangled. Coat the pin slots with epoxy to insulate all metal or wire near the connector from the tissue.
