Electrical connector with external load bar, and method of its use

1. A modular plug system including:

a plug housing including a top surface, bottom surface and two opposing side surfaces, a front end and an opening opposite the front end, and a cavity extending from the front end to the opening in the back end with a plurality of openings extending through the front surface to the cavity;

a plurality of guide units in the cavity positioned such that each of a plurality of wires engages a respective guide unit;

a cutting surface extending from a lower portion of the front end such that the cutting surface is below the lowest row of openings, where the cutting surface is sized to accommodate two pillars on a crimping device with the two pillars being positioned on opposing sides of the cutting surface when the tool engages the plug,

wherein each guide unit is aligned with a respective opening; and

wherein the cutting surface has a thickness sufficient to stay connected to the front surface after a cutting device engages the cutting surface.

2. The modular plug system of claim 1 wherein the guide unit are sized such that the wires are secured tightly in the plug cavity.

3. The modular plug system of claim 1 wherein the openings are arranged in a single row.

4. The modular plug system of claim 3 wherein the openings are arranged in two rows.

5. The modular plug system of claim 1 wherein the openings are arranged in more than two rows.

6. The modular plug system of claim 1 wherein the openings in the front end are interconnected.

7. The modular plug system of claim 1 wherein the front openings are sized to engage a wire extending through each opening.

8. The modular plug of claim 1 wherein the top of the cutting surface is co-planer with the top surface of the pillars.

9. A method of forming a modular connector, the method including the steps of:

forming a plug housing including a top surface, bottom surface and two opposing side surfaces, a front end and an opening opposite the front end, and a cavity extending from the front end to the opening in the back end with a plurality of openings extending through the front surface to the cavity;

forming a plurality of guide units in the cavity positioned such that each of a plurality of wires engages a respective guide unit;

forming a cutting surface extending from a lower portion of the front end such that the cutting surface is below the lowest row of openings, where the cutting surface is sized to accommodate two pillars on a crimping device with the two pillars being positioned on opposing sides of the cutting surface when the tool engages the plug,

aligning each guide unit with a respective opening; and

wherein the cutting surface has a thickness sufficient to stay connected to the front surface after a cutting device engages the cutting surface.

10. The modular plug system of claim 9 wherein the guide unit are sized such that the wires are secured tightly in the plug cavity.

11. The modular plug system of claim 9 wherein the openings are arranged in a single row.

12. The modular plug system of claim 11 wherein the openings are arranged in two rows.

13. The modular plug system of claim 9 wherein the openings are arranged in more than two rows.

14. The modular plug system of claim 9 wherein the openings in the front end are interconnected.

15. The modular plug system of claim 9 wherein the front openings are sized to engage a wire extending through each opening.

16. The modular plug of claim 9 wherein the top of the cutting surface is co-planer with the top surface of the pillars.