"Will" bravely wrote to "All" (14 May 05 13:38:12)
--- on the heady topic of "How solder to very fine enamelled woven wires in
earphone lead?"

Wi Subject: How solder to very fine enamelled woven wires in earphone
Wi lead? From: Will
Wi Xref: aeinews alt.engineering.electrical:22349
Wi sci.electronics.components:13939 sci.electronics.repair:48119
Wi sci.electronics.basics:27822

Wi I have some Sony in-ear headphones. The lead to one earpiece has
Wi been cut through completely and I want to rejoin the two wires
Wi (which I will call 'conductors' to avoid confusion).

Wi The two 'conductors' inside the lead are rather thin. And what is
Wi more, each of the two 'conductors' is made up of something like a
Wi dozen smaller copper wires which are woven around some very fine
Wi threads (perhaps the threads are very fine polyester yarn). The
Wi threads run along the lead as the core of the 'conductor'.

Wi The wires of one of these two 'conductors' looks like bare copper
Wi and is unoxidised so I can probably solder to it. But the OTHER
Wi CONDUCTOR is the PROBLEM because its fine wires are enamelled.

Wi How can I remove this enamel coating in order to be able to solder
Wi to the fine copper wires of the 'conductor'?


There is an enamel stripping liquid available in electronics supply
stores. I generally just run a hot tip over it to singe the enamel a
little then dip the end into paste flux. It usually works but if it
turns into a burnt mess I didn't do it right and start over.
There is also electric arc welding flux which is based on hydrochloric
acid. If this doesn't get the enamel off then nothing will! ;-)

A*s*i*m*o*v

.... "Bother!" said Pooh, as he saw the sparks and smelled the smoke.