Re: [DML] Fuse box replacement

[Paul Gress <pgress@xxxxxxxxxxxxx>]

Base on my knowledge as a professional electrical wirer.

1) You need to tin the soldering iron first prior to applying heat to the connection.  The applied solder will help surround the wire transferring heat.  A dry tip cannot transfer heat adequately to flow solder.

2) A soldering gun should be avoided due to uncontrolled tip temperature.  I can literately overheat the solder joint and become flux embrittled.

3) Prior to soldering you should have a good mechanical connection.  Solder is not intended to mechanically secure wire joints, it is considered to seal the connection (don't bring up surface mount components or solder splices [Raychem], different theories).

4) Try to keep the solder only at the joint, if solder wicks under the insulation you risk allowing vibration to add additional stress at that point.



Paul









On 08/27/12 03:52 PM, soma576 wrote:
> Hey all,
>
> 11596 is getting a new fuse box.  I've had a few of the critical fuses in jumpers for well over a decade.  I always hated messing around in my electrical compartment for fear of knocking something loose and causing Bad Things.
>
> I got the new fuse box kit from DMCMW and a proper barrel crimper.  Not only am I crimping everything perfectly but I'm also soldering the connections.  Should be trouble-free for a long time.
>
> Anyway the kit is coming along nicely but as you can expect it takes a long time to do right.  Took me about 4 hours just to do 7 fuses last night.  After crimping and soldering I'm putting 3/4" of heat shrink tubing on the connection.
>
> One thing that baffles me is how long it can take to heat up the connection so the solder will flow.  I'm using a 140 watt gun-style iron with flat blade tip.  Once the tip is hot I can melt the solder on the tip in less than a second, but it often takes well over a minute to heat up the connector.  It might have something to do with "tinning" the tip - once I flowed some solder onto the tip, shook it off, then went right for the connector which took solder in under 3 seconds.  Other times it takes what seems like forever.
>
> Anyone have any great tips to make this go faster?
>



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