A plastic connector housing (50) having a plurality of contacts secured therewithin is securable to and within a protective metal shell (12) without a bead of liquid adhesive placed therebetween during assembly, by forming a shallow peripheral channel (76) in a housing flange forward surface (74) and a shallow recess (30) in an abutting rearward surface (24) of a corresponding shell flange (18), the channel and recess defining a confined seal seat (80) extending around the housing body section (70). Lengths of solid sealant preforms (90) such as of epoxy are disposed along the channel during assembly, and the shell (12) and housing (50) held together and heated, thereby melting the sealant to flow and bond to the surfaces of the channel and recess, both joining the housing (50) to the shell (12) and forming a hermetic seal (92) along the interface therebetween, recessed from outer surfaces of the connector (10).