Soldering wires to deans-T connectors is a very important process.
There are two best methods of the soldering 'at home'. Both are characterized by a very low resistance.
Suggested tools:
Soldering iron
Solder, rosin
Pliers
Tweezers
Small vice
Sandpaper 600 (or finer)
Paper knife
Pincers
Scissors
Lighter
ATTENTION
Electrical resistance of solder is six times higher than resistance of copper. In general, solder serves as mechanical and electrical connection.
Always use flux or rosin when soldering. This is necessary to achieve the correct connection.
The 0.5 mm diameter wire can be made out of 8-conductor cable UTP (unshielded twisted pair).
It is suggested to use a copper wire, as an aluminum wire is prone to breaking.
FIRST METHOD
Deans-t connectors preparation:
Clean out with fine sandpaper the part that is going to be soldered
Cover it with a thin layer of solder (always use flux or rosin during soldering, especially when the solder melts. This is necessary to achieve the correct connection).
Remove excess solder
2. Wire preparation:
Put 2 cm of heat shrink tube on a wire
Take off the wire’s insulation to the desired length - about 6mm (using a knife, score carefully the external part of the silicone insulation. Then use your nail to pull it away)
Never twist subcables in a wire (twisting increases space between the subcables, which is going to be filled with solder)
3. Wire fitting and soldering
Attach the stripped wire to the contact
Pulling strongly, coil the contact around with the additional 0.5 mm diameter wire
Pour over the wires with solder. The tightly twisted wires should perfectly fit the contact
4. Connection verification
Have a look at the connection and check if it is done properly. Pay attention to solder – it should fill soldered space correctly and solder should not be oxidised
Try to pull out the wire
5. Protection of the soldered connection
Remove excess rosin from the connection
Prepare heat shrink tubes and close them
Heat the heat shrink tube carefully from all sides. Do it over the flame of a gas range or lighter
SECOND METHOD
Second method is easier than the first one, but the connection parameters are a bit worse than in the previous method.
1. Deans-T connectors’ preparation:
Clean out with fine sandpaper the part that is going to be soldered
Cover it with a thin layer of solder (always use flux or rosin during soldering, especially when solder melts. This is necessary to achieve the correct connection).
Remove excess solder
2. Wire preparation:
Put 2 cm of heat shrink tube on a wire
Take off the wire’s insulation to the desired length of about 6mm (using a knife, score carefully the external part of the silicone insulation, your nail should pull it away)
Twist the subcables at a slight angle
Apply solder to the wire ends
3. Soldering wire to the contact
Attach an end of wire to the contact, and hold it firmly with tweezers (using great force ensures the right connection)
Heat it and pour over with solder
4. Connection verification
Have a look at the connection and check if it is done properly. Pay attention to solder – it should fill soldered space correctly and solder should not be oxidised
Try to pull out the wire
5. Protection of the soldered connection
Remove excess rosin from the connection
Prepare heat shrink tubes and close them
Heat the heat shrink tube carefully from all sides. Do it over the flame of a gas range or lighter
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