Soldering: first steps

1. Take two short lengths of copper wire with a conductor area of approximately 1.5 mm ²,
   (1.5 square mm). Suitable wire can be obtained by stripping the insulation from a length of
   1.5 mm ² twin and earth flat domestic wiring cable.

   

2. Take a penknife or single sided razor blade. Scrape each length of copper wire until approximately 3cm at the end of each wire is bright and shiny.

   

3. Clamp each wire in turn in a miniature vice or a "helping hands" apparatus.
4. Take some multicored solder in one hand and your soldering iron in the other. Apply heat from the tip of the iron to the copper wire.
5. When the copper wire is hot enough to melt the solder, run the solder along the shiny 3cm of each copper wire.

   

   This process is known as "tinning" the surface.

   

6. Take a pair of electrician's pliers. Twist the shiny ends of the two wires together, making a good mechanical joint.

   

7. Clamp the wires in a miniature vice or a "helping hands" apparatus.
8. Apply heat from the tip of the iron to the copper wires at the twisted join.
9. When the copper wire is hot enough to melt the solder, run the solder along the join. Use just enough solder to infill between the two copper wires.

   

10. Allow the copper wire to cool and the scrape away any resin flux.
11. Examine the soldered join carefully. If the solder is dull grey in appearance, reheat the joint and apply a little more solder and flux. The solder should be evenly spread and a bright silver colour when newly made.

A soldered joint made in this way will have

• good mechanical strength
• good electrical conductivity

Keep the tip of your soldering iron clean by wiping it periodically on a damp sponge,(which can be obtained from soldering iron stockists).

Soldering iron bits are usually copper clad with iron and flashed with nickel for longer life. They should not be scraped or filed or they will quickly disintegrate.

Molten solder melts man-made fibres and sticks to woollen garments. Wear an old cotton shirt or cotton based overall when soldering.

Work in a well ventilated area. Fume extraction attachments are available for some irons.

When (not if :) you burn yourself, quickly run cold tap water over the burn to dissipate heat and limit tissue damage.

For safety, always park a hot iron in a bench stand.

Unattended soldering irons should be switched off.

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