Soldering problem

[Rikki Kitto]

Anyone know how to connect new plugs to a set of headphones, trying to fit better speakers to my motorcycle helmet loom and the wires are so thin soldering iron will just melt them

[borderS2]

Tin the thin wire by making a puddle of Solder on a scrap of wood, using the soldering iron to keep it molten and dipping the wire in the puddle. Trim the tinned tip to 3mm. Make sure the plug terminals are tinned and only apply heat to this. bring the wire into contact with the terminal and remove the soldering iron. I have also seen this done by tinning both, wrapping the wire around the terminal several times and watching very carefully for the melt point when heat is applied. If you have an old, "domestic" soldering iron, replace the tip or file a new profile and tin before use. You might find it easier to put tails of another wire between the cable and the plug. Hot glue or a small cable tie can help to protect your joints from mechanical strain, you don't want to have to solder them again.

[prj]

You don't need to make any pools.
Use the correct rating soldering iron. If you are soldering fine wires, then use a 25-30W soldering iron.

Or even better, use a temperature controlled soldering station.

Watch this video:

http://www.youtube.com/watch?v=I_NU2ruzyc4

Watch it until you understand and take in every single word he says. It is pure gold.

[borderS2]

Yes, Prj is correct, a controllable iron is best. I have a workbench temp controlled iron but also use a Weller Pyropen. A bit like this: http://www.ebay.co.uk/itm/PORTASOL-O...ht_2253wt_1074
It is controllable as well as portable.

[Rikki Kitto]

Cheers guys very helpful as always, love this Forum

[chezz]

I used silver solder and Rosin flux (non corrosive) on my Kuzma Stogi turntable arm...Van Den Hul cable is extremely fine and a total bitch to solder.