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Electrical repairs can appear to be difficult and daunting tasks. The truth is that many common electrical problems are the results of broken wires. Soldering broken wires together is the absolute best way to ensure the connection is repaired permanently. To obtain a soldered wire connection that will be long lasting, it is important that the solder joint is made correctly and fully cleaned.
Preparation:
First, before any soldering job can be started it is important to have all the necessary tools and supplies on hand. You will need your soldering iron, solder and flux, wire strippers, needle nose pliers, heat shrink tubing or electrical tape, rubbing alcohol, and a rag or cotton tipped applicators.
Safety:
I would like to pause here for a few words about electrical safety. Before you attempt any kind of electrical repair ENSURE that all power has been shut off and removed. If you are attempting to solder inside an appliance or other electrical device, be aware that even with the appliance unplugged it is possible to get a huge shock! Many appliances have power supplies with large capacitors, which can hold a substantial charge for a long time. I would advise against attempting such a repair and encourage you to contact a local repair shop.
Soldering:
Once you have assembled all the necessary items, it is time to prep the wires to be soldered together. The first step is to strip about ? in of insulation of the ends of each wire. Once both wire ends have been stripped, the bare wire must be ¡®tinned¡¯. Tinning the leads before soldering will make the ending solder joint much stronger. Tinning involves applying solder to each end individually. First, take one wire and apply a dab of flux to the bare wire. Now, using the preheated soldering iron, apply the solder down the length of exposed wire. While tinning, be sure to try not to damage the insulation on the rest of the wire too much. A little bubbling of the plastic is ok, and repairable, though it should be kept to a minimum. (Note: tinning can be almost more difficult than creating an actual solder joint. I would recommend practicing a few times on a piece of scrap wire)
Now that you have two tinned wire ends, it is time to solder our joint. At this point, you need to cut a piece of heat shrink tubing to the appropriate length as to which will overlap the remaining insulation on both sides of the joint. Slide the heat shrink over one wire before continuing. Using a pair of needle nose pliers, bend each tinned wire end into a hook. It is a good practice to keep your hooks as tight and thin as possible. While making your hooks, if the hook¡¯s ends are bent slightly inward it helps maintain the integrity of the heat shrink. Next, you ¡®hook¡¯ the two hooked wire ends together. Apply some flux to the wires, then using your soldering iron, heat the flux and apply a little solder to form the joint. It is good practice to keep the amount of solder on the joint to a minimum. Compare this to gluing to sticks together. You want to use enough to do a proper job, but you also don¡¯t want to get crazy with it.
Once the new soldered joint has hardened, you must now clean off any and all remaining flux. This is essential since most common fluxes are corrosive. Any remaining flux will slowly eat away at the solder joint and eventually cause it to break. I recommend using cotton tipped applicators and rubbing alcohol, but any non-corrosive household cleaner would work fine. After the joint is cleaned and dry, it is time to repair the insulation. If you had heat shrink installed on the wire, slide it over the solder joint and apply heat with a hair dryer, or lighter. Otherwise, if you did not use heat shrink, electrical tape is a great substitute. Ensure that the joint and all bare wire is covered completely. Bare wires have been the cause of everything from shocks to house fires.
By following this guide, you can repair anything from extension and power cords, to speaker wires.
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