Patent ID: 7437819

Claim:
A method for making a sealed underwater connector having an annular transition end from an electrical connector and a cable extending therefrom comprising the steps of: applying a protective coating on said annular transition end, said protective coating having irregularities; providing mold halves having a boot molding cavity, and an annular resilient seal cavity for molding a waterproof boot around the annular transition end of the electrical connector; placing the electrical connector and the cable in said mold halves; providing an annular resilient seal having an annular inclined surface about the electrical connector and the cable when positioned within said annular resilient seal cavity of said mold halves; sealing the mold halves together with the electrical connector, cable and annular resilient seal positioned in the boot molding cavity and the annular resilient seal cavity; filling said boot molding cavity of said sealed mold halves with a castable elastomeric material, said castable elastomeric material causing compression of said annular resilient seal against said connector and preventing leakage of castable elastomeric material along said connector; and removing said connector, said cable and said boot molding from said sealed mold halves after said castable elastomeric material has set.