On Friday, December 21, 2018 at 11:52:22 AM UTC-5, Joseph Gwinn wrote:
On Dec 21, 2018, DerbyDad03 wrote
(in ):

Keeping this relevant to the wRec, the following video shows us how to replace
the power cord on a circular saw.

If you start at 4:30, you will see a technique for creating a "ring connector"
from the bare power cord wires. What do think of this technique?

https://www.youtube.com/watch?v=61e5xG4kqXE

I have some issues with some of the other things he says and does in the
video, but this question is mainly about the connection method he uses.

The proper method is to crimp a ring crimp terminal onto the wires, if there
is space -- which looks questionable in this case.

In the old days, manufacturers crimped a hollow brass eyelet around the
stranded wire, creating a solid metal ring, but I have not seen that in ages,
and it wasn´t something that one could afford to do at home anyway.

Failing that, I twist the copper strands into a solid bundle and tin the
bundle with liquid rosin flux and radio solder, making a solid wire. This is
bent around the terminal screw in the direction of tightening, and the screw
is tightened. The wrap direction is critical to ensure that the wire does not
squeeze out from under the terminal screw.

One could also form an eyelet as shown in the video, and then tinned the
copper wire to solidify the ring.

The key is to ensure that thge terminal screw cannot cut the wire while being
tightened.

.
I would not have drilled the plastic to get to the torx screws in the plastic
handle. One can get torx screwdriver inserts with 6" shafts.

That was one of my issues also. In fact, on that model saw, the Torx screws
are also slotted. A narrow flat blade screw driver works just fine in the
deep handle hole.


I could not see how the cable was clamped on entry to the saw handle, but
this area is critical.

The handle itself clamps the cord in 2 places.

1 - The hole formed by the 2 piece handle for the stress relief sleeve is
smaller than the sleeve itself.

2 - Interior from that, the handle pieces form another "hole" that has a
straight plastic bar across it. As long as you leave the outer insulation
on the cord, you basically need a clamp to close the handle before screwing
it back together. You could use the screws to pull it together but I don't
like putting that much stress on screws going into plastic.