Who can weld this?

[Martynf]

I made a bit of an expensive mistake today with one of my xenon bulbs. I broke the earth return wire rushing to put them back in the car and I bashed the bulb and broke it

The 'wire' will not solder, it just won't take the solder. Can anyone weld this??

Martyn

[Pisobiker]

It depends on wire material. I take it is not copper, otherwise solder would have worked. Castolin silver welding should work with any iron/brass based alloys. In this case you need a thiny oxy-acetylene flame welder and a silver welding bar to do the job. As soon as the two ends become hot red you can join them adding a small amount of rod. Wire might be aluminum (?), wich needs a different rod alloy, and when welding you cannot wait it becomes red hot! Aluminum doesn't. If you go too far on heating up it just melts and suddenly collapses !

How much does the bulb cost? Is it worth the assle?

Marco

[jas11n2003]

broken bulb

If you go to a good electronic retailer (we have a company up here called Maplins, not sure if you have them further south) or RS springs to mind, you can get a special acid flux solder which will do the job. We have used it in the past for soldering to mild and stainless steel.
Hope this helps

[jas11n2003]

will also solder to alloy. Just watch your eyes (wear some glasses) as it spits like mad.

[Martynf]

Thank you guys Marco, they are about 60 Uk a bulb, so its worth trying first!

Thanks Jas, that sounds workable to me!! I have a maplins 10 miles away, time to visit them this weekend.
Thank you very much!
Merry Christmas!
Martyn

[newsh]

That is almost certainly a spot weld.

[audiman]

Not a chance of welding that, its just to small and a welder will just blast it to bits. You muppet!!!!

Looks like you have nothng to lose, just try some gaffa tape or cable ties. Team Bodge style!!! Bound to work

[newsh]

Hey, they just use a very small welder!! LOL

Originally posted by audiman
Not a chance of welding that, its just to small and a welder will just blast it to bits. You muppet!!!!

Looks like you have nothng to lose, just try some gaffa tape or cable ties. Team Bodge style!!! Bound to work

[SteveH]

Martyn...If you can't solder/weld it, try a mechanical joint. Strap the two connections together with a twist of stainless or copper wire. If it's good and tight, it shouldn't be a problem. If it's loose, it will probably melt the wire you use to connect them. You've got nothing to loose if you try it and it fails

[Sidspud]

Or you could try something like what my dad used to do when a household fuse blew. Simply wrap a bit of tinfoil around it! :eek2:

I'm still alive and the house never buned down so it's bound to work!

[Martynf]

you guys!! hey but I like the wrapped with thin wire first, then acid flux solder it over the top, yes! good idea!!

It's not iI'm tight or anything, just all my pennies are going towards more bhp, I don't wanna spend a penny on anything that don't make it go faster...

[Pisobiker]

...and better "hold" you in the car...





Marco

[Greg_S]

martyn you could try using a smal piece of bent wire then doing a long solder joint onto each piece to make a good joint between them?

[Stick Insect]

I'm not sure what the ambient temperature around the bulb is but if you 'solder' it then once the bulb warms up it will melt the solder and the connection will be lost.

'Solder' ususally refers to lead solder.

Silver solder requires a much higher temperature and requires a mini blow torch. which may be an option

Wrapping thin wire around it will provide a mechanical joint.

Without seeing a better diagram I would agree with the spot weld theory. I have a spot welder and feel that this may be the best way to repair it. I will gladly have a go ( at your risk) if you wish. I can send you a direct e-mail for my address if you wish.

[Martynf]

Why thank you for the offer

I cleaned the two parts to be soldered and coiled some thin copper wire around the two parts to give a fighting chance for the sodler to hols. So far..... it's working fine. The ambient temp is a good point for melting the solder. We'll see after a period of time if the repair holds. Thank you VERY much for the offer! might be back to you....


Martyn
p.s still cannot find the towabr - and its buggin me now!