On 23 Aug 2005 13:58:15 -0700, "
wrote:

I got an email response from the customer support. The guy said the
spoke with production and they told him it was possible to get to the
pin in question by using a dremel tool on the expoxy potting. The pin
seems to be broken within the wall of the speaker (about 5/8 inch
thick, corian like material). I've carefully dremelled enough material
away(about 1/2 inch depth) to see a bit of the rest of the pin.

Now I'm taking a break before I screw things up. I understand that one
can really f**k things up with a dremel tool.

I've ordered a replacement pin through a dealer so I can see what I'm
dealing with.

What I think I might do is get some more of the pin exposed and find a
place where I can place a proper solder point. I would then cut the
original pin at that point, cut the replacement pin to match and solder
them together. I'm sure this will be stronger than what I'm doing now
since when I pull the pin out in it's current state of disrepair there
is solder bonded to the external portion which I heated; it appears the
solder is not well bonded to the stump embedded in the speaker,
probably since that part isn't hot.

Now you're getting somewhere!

Can you tell if the broken pin is made of stainless steel? If not,
do you have a broken off piece that someone could examine?

You'd probably get a stronger joint if you have a bushing or collar
made that would enclose both the stub and the new pin -- or have a pin
made that has a larger section with a hole that surrounds the stub.

If you can accurately measure the diameter of the stub (with calipers,
not a ruler) and make a sketch, I would be glad to machine a part for
you. Contact me by email if that is of interest.

If the material is stainless steel, then I would recommend a
tin-silver solder for joining them. I could send you a bit of that.
It melts at 430F, not greatly different from ordinary lead-tin solder,
but it is a lot stronger and it wets just about any ferrous or
copper-bearing metal -- steel, stainless, copper or brass.