Re: soldering?

[David Roden <roden@ACORN.NET>]

> Unless you have industrial
> soldering equipment, it is not possible to get everything evenly heated, and
> you will get a cold joint.

As I mentioned, a propane torch heats the lug quite well.  You need to
sweat it for some time after the solder flows into the lug to make sure
it soaks into the wire thoroughly.

Also, do not under any circumstances use acid (plumbing) flux.  Use Kester
TV-radio soldering paste.  I should not have said I "dunk" the cable in
the flux.  The flux should be brushed into the copper cable somewhat
sparingly.  Also, wire brush the inside of the tubing and lightly coat it
with flux before shoving the cable end in.

> Also, the solder will wick up into the cable,
> making it stiff, and making the strands brittle and subject to breakage.

I agree, this is a negative of the method.  You must be careful not to
allow flexing near the terminal.

And Mike's right about the heat damage to cable insulation.  A long piece
of shrink tubing will cover it.

I have a great deal of respect for Mike, and his position is a good,
moderate one.  If you have a hex crimper, or even a hammer crimper, by all
means use it.  If you are running high voltages and/or currents in a
performance EV, don't even think of using anything but a hex crimper (or
professionally assembled cables).

I won't say my method is better than a good crimper.  It isn't.  But it
has worked reliably for me in my cars, which are *not* high performance
beasts.



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   David Roden         THE VIRTUAL PD            roden@acorn.net
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Re: soldering?                                                               R