(Borrall Wonnell) writes:

Hi all,

I am trying to add a surface mount phono (RCA) jack to an existing 12V
line. Unfortunately, the connection needs to handle some mechanical
stresses. I have switched the line from solid core wire to stranded
in an effort to reduce the stress, but the solder connection still
fatigues after a few mechanical cycles.

Has anyone else dealt with a similar situation for strain relief? I
have a limited amount of space to work with (perhaps 0.5"). Will
simple heat-shrink tubing help here? Will I need something more
robust (a thicker plastic sleeve perhaps)? Should I practice my
soldering technique?

FWIW, the wire I am using is 18 gauge.
Constructive comments will be appreciated!

Solder is not glue!!!

You have to use something else to provide the mechanical support.
The wire should not be pulling on the solder.

Not being able to see what you are dealing with is a problem but the wire
will have to be anchored somehow (wrapped around a peg, cable clamped,
embedded in hot-melt glue, etc. Then, adding some heat shrink or plastic
tubing to distribute the bending stress over a larger area.

We may need to also look at your soldering technique.....

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