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Jeff Liebermann Jeff Liebermann is offline
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Default How to solder very thin stranded wire?

On Thu, 21 Feb 2013 11:25:48 -0800, notme wrote:

I don't understand the technique.


Sorry. I couldn't tell if it was coated or bare tinsel.

The wire is enameled (insulated). Do I prepare the wire by burning (or
sanding) off some of the enamel first?


Take a knife and scrape off some of the insulation. You don't need to
remove all of it or completely, just enough to make at least one
connection to the wrapping wire.

I start wrapping back a way and wrap toward the end of the wire?


Yes. The part that goes over the insulation acts as a mechanical
support to prevent breakage where the insulation ends. It's not
necessary to tightly pack the windings together. A loose spiral is
sufficient as long as there are multiple points of contact with the
tinsel.

Then I solder not the tinsel wire but only the wrapping wire beyond the end
of the tinsel wire?


Correct.

This looks like there is no actual soldering of the
tinsel at all (which is intentional, I presume, to avoid stress points).


Correct. You just need a mechanical connection. If this were some
device that carried some current, such a method would not be suitable.
However, since EP/Mic audio is very low power, a simple mechanical
connection is sufficient.

Incidentally, I learned this method back in the 1960's during my phone
phreaking days, when fixing tinsel telephone coil cords was became a
side business because nobody had cheap replacement coil cords or
insulation piercing spade lugs.

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