I have a Seasonic FOCUS-SPX-650. Since sleeved cables are often times out of stock and too long for my use case, as I use the PSU in an ITX system, I decided to build the CPU, PCI-E and ATX cables by myself.
The CPU cable was no problem, I just copied the original cable. However, the ATX cable is not that trivial. The reason for that are the sense wires for the PSU which result in 10 + 18 pins on PSU side (= 28 in total) while only using 24 on mainboard side (ATX plug).
Seasonic resolved this issue by just crimping two cables into one Mini-Fit Jr terminal. They use the same gauge (= 2 x 16 AWG) for both the current and the sense cables. While I wonder how they did that, I know that I can't do that, because the terminal will only take one or multiple cables totally not exceeding 16 AWG. Even if I use 17 or 18 AWG it will be too thick.
What I thought about is just crimping 17 AWG for current and 23 AWG for sense together. That works, the crimp is fully cosed. However, what I do different is that I don't make it directional, I just strap it by using the cable as a jumper. Please see the photo above so that you can see what I mean:
My questions are:
Is the jumper approach a good idea? Does it have any drawbacks other than it may not look that good (however, as it is on PSU side, I do not care at all).
Is 23 AWG enough for the sense wires? I assume that the sense must have a high resistance, so there can't be much current on it.
Is it fine to crimp two cables together as long they together do not exceed 16 AWG?