DIY: How to Solder Wire

Difficulty Level

Tools/Supplies Needed:

• rosin core solder
• soldering iron
• heat gun
• wire strippers or cutter
• wire
• heat shrink tube

Procedure:

• ensure the wires you are working are free of any corrosion
• solder in a well ventilated area
• strip the insulation off the ends of the wires you are wanting to solder about 2cm (3/4")
• cut heat shrink tube to length and slide it onto the wire before you start the soldering process
• heat shrink tube should be about 5cm (2") in length
• separate the wire strands, then twist the two exposed conductors together
• allow the soldering iron to heat up
• before soldering, ensure the heat from the soldering iron and soldering won't affect the heat shrink tube
• once the soldering iron is hot, hold it up the spot you are soldering for about a minute (depending on how hot your soldering iron operates at)
• put a small dab of solder on the tip of the soldering iron
• allow that dab of solder to flow into the wire strands
• once it flows in, continue to add more solder
• ensure that enough solder has been added to the connection so the area is coated and secured
• be sure to get it right the first time as the solder doesn't tend to flow as smoothly if heated up more than once
• allow the joint to cool
• move the heat shrink tube over the freshly soldered joint, ensure it is centered
• using a heat gun, warm the shrink tube and it will shrink on the newly soldered joint
• when heating the heat shrink tube, ensure that you go around the whole perimeter rather than just one side as that enables the heat shrink tube to contract evenly
• do not hold the heat gun on the heat shrink for an excessive amount of time as you can burn the heat shrink

Frequently Asked Questions (FAQ):

Can a hair dryer be used instead of a heat gun?

Yes it can be.

Video tutorial on how to solder copper wire and apply heat shrink tube. The type of solder that was used was rosin core and the type of wire used in the video is cross link which is quite common in automotive or electronic applications. Rosin paste flux is not required for this application as we are using rosin core solder instead. Rosin is intended to help the solder flow better while also adhering to the objects you are working with. This method also works with standard strand wire. Electrical tape can be used to provide protection on the soldered joint, but shrink tube is a much better method. Shrink tube will provide a better insulation, looks cleaner, will last longer, and is much more resistant to moisture. Heat shrink normally comes in black, but can also be purchased in specific colors to match the wires you are working with. There is also heat shrink tube available that has an internal adhesive which allows for a perfect water tight connection. Be sure to solder in a well ventilated area.