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UK diy (uk.d-i-y) For the discussion of all topics related to diy (do-it-yourself) in the UK. All levels of experience and proficency are welcome to join in to ask questions or offer solutions. |
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#1
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Soldering flexible cord (headphones)
I have a pair of quite expensive (well by my reckoning) Bose noise
Cancelling Headphones. The 3.5mm 3 pole stereo plug needs replacing - intermittent contact of one core. Bought a quality gold plated right angle plug, which comes with neat stress relief bushes. The issue is the flexible cord itself .... it is a thin very flexible item ... the cores once exposed are not individually sheathed in pvc ... but what seems like a woven sheath thst just frays if you try to strip with a knife. The overall diam of cable is 1.9mm The diam of each insulated core is 0.39mm If that helps give an idea of cable type ...I have taken a pic: http://i771.photobucket.com/albums/x...psaac86758.jpg Is there a particular technique to soldering these ...... the issue is stripping the cores, it just seems to fray and get in a mess. Don loads of cable soldering in the past ... but prepping the ends on this cable is proving difficult |
#2
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Soldering flexible cord (headphones)
Am 12.01.2013 17:06, schrieb Rick Hughes:
[soldering problem] If that helps give an idea of cable type ...I have taken a pic: http://i771.photobucket.com/albums/x...psaac86758.jpg Is there a particular technique to soldering these ...... the issue is stripping the cores, it just seems to fray and get in a mess. Just an idea (may be a bad one): Try to burn off the insulation with a pencil torch or even (if not at hand) a lighter. May work, if the insulation is cotton-based. Hope you understand, what i'm trying to say. BZW: I apologize for my bad English. I am a Kraut. Greetings Matthias |
#3
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Soldering flexible cord (headphones)
"Matthias Czech" wrote in message ... Am 12.01.2013 17:06, schrieb Rick Hughes: [soldering problem] If that helps give an idea of cable type ...I have taken a pic: http://i771.photobucket.com/albums/x...psaac86758.jpg Is there a particular technique to soldering these ...... the issue is stripping the cores, it just seems to fray and get in a mess. Just an idea (may be a bad one): Try to burn off the insulation with a pencil torch or even (if not at hand) a lighter. May work, if the insulation is cotton-based. These cables can sometimes be a bundle of thin enamelled copper wires, with the varnish in different colours for identification. The idea is to give a thin flexible cable that survives bending well. It's often used in RF applications (Litz wire) as it has good high frequency characteristics, although this will be of rather less impotance at audio frequencies. http://en.wikipedia.org/wiki/Litz_wire Soldering it mainly involves getting the end of the bundle hot enough to cook off the enamel - so a decent sized iron, at a slightly higher temperature if possible, usually does the trick. Charles F |
#4
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Soldering flexible cord (headphones)
On Sat, 12 Jan 2013 16:06:52 +0000, Rick Hughes
wrote: I have a pair of quite expensive (well by my reckoning) Bose noise Cancelling Headphones. The 3.5mm 3 pole stereo plug needs replacing - intermittent contact of one core. Bought a quality gold plated right angle plug, which comes with neat stress relief bushes. The issue is the flexible cord itself .... it is a thin very flexible item ... the cores once exposed are not individually sheathed in pvc ... but what seems like a woven sheath thst just frays if you try to strip with a knife. The overall diam of cable is 1.9mm The diam of each insulated core is 0.39mm If that helps give an idea of cable type ...I have taken a pic: http://i771.photobucket.com/albums/x...psaac86758.jpg Is there a particular technique to soldering these ...... the issue is stripping the cores, it just seems to fray and get in a mess. Don loads of cable soldering in the past ... but prepping the ends on this cable is proving difficult It's tinsel wire and is very difficult to deal with. What I do is to try to tin it with the iron anf hopefully melt the insulation, then find the finest strand of copper wire you can get your hands on and wind it around the end then apply a little mote solder on order to make a sort of bootlace ferrule. -- Graham. %Profound_observation% |
#5
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Soldering flexible cord (headphones)
On Sat, 12 Jan 2013 16:06:52 +0000, just as I was about to take a
herb, Rick Hughes disturbed my reverie and wrote: Is there a particular technique to soldering these ...... the issue is stripping the cores, it just seems to fray and get in a mess. A delicate touch is required. A sharp modeling knife/scalpel would help. -- Cheers DrT ______________________________ We may not be able to prevent the stormy times in our lives; but we can always choose whether or not to dance in the puddles (Jewish proverb). |
#6
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Soldering flexible cord (headphones)
On 12/01/2013 17:53, Graham. wrote:
On Sat, 12 Jan 2013 16:06:52 +0000, Rick Hughes Don loads of cable soldering in the past ... but prepping the ends on this cable is proving difficult It's tinsel wire and is very difficult to deal with. What I do is to try to tin it with the iron anf hopefully melt the insulation, then find the finest strand of copper wire you can get your hands on and wind it around the end then apply a little mote solder on order to make a sort of bootlace ferrule. +1, although I have also sometimes used a tiny gas torch as another poster suggested. Another technique which used to be used on Litz wire was dipping the end in meths and setting light to it, followed by gentle scraping (but that was an enamel, not a fibrous insulation) |
#7
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Soldering flexible cord (headphones)
On 12/01/2013 17:12, Matthias Czech wrote:
I am a Kraut. Herzlichen Dank mein Herr |
#8
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Soldering flexible cord (headphones)
On 12/01/2013 17:48, Charles Fearnley wrote:
These cables can sometimes be a bundle of thin enamelled copper wires, with the varnish in different colours for identification. That what is appears to be ... |
#9
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Soldering flexible cord (headphones)
On 12/01/2013 22:15, newshound wrote:
On 12/01/2013 17:53, Graham. wrote: On Sat, 12 Jan 2013 16:06:52 +0000, Rick Hughes Don loads of cable soldering in the past ... but prepping the ends on this cable is proving difficult It's tinsel wire and is very difficult to deal with. What I do is to try to tin it with the iron anf hopefully melt the insulation, then find the finest strand of copper wire you can get your hands on and wind it around the end then apply a little mote solder on order to make a sort of bootlace ferrule. +1, although I have also sometimes used a tiny gas torch as another poster suggested. Another technique which used to be used on Litz wire was dipping the end in meths and setting light to it, followed by gentle scraping (but that was an enamel, not a fibrous insulation) I have a micro gas burner I'll try that |
#10
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Soldering flexible cord (headphones)
On 12/01/2013 20:41, DrTeeth wrote:
On Sat, 12 Jan 2013 16:06:52 +0000, just as I was about to take a herb, Rick Hughes disturbed my reverie and wrote: Is there a particular technique to soldering these ...... the issue is stripping the cores, it just seems to fray and get in a mess. A delicate touch is required. A sharp modeling knife/scalpel would help. -- There are a mass of wires in each core ... as I try to scrape they just all come open and stand a real risk of shorting. Wonder how they manage during manufacture |
#11
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Soldering flexible cord (headphones)
On 12/01/13 22:47, Rick Hughes wrote:
On 12/01/2013 17:48, Charles Fearnley wrote: These cables can sometimes be a bundle of thin enamelled copper wires, with the varnish in different colours for identification. That what is appears to be ... worse sometimnes it 'tinsel' which is wires interspersed with fibres good for flexcibility: almost impossible to solder at all -- Ineptocracy (in-ep-toc-ra-cy) €“ a system of government where the least capable to lead are elected by the least capable of producing, and where the members of society least likely to sustain themselves or succeed, are rewarded with goods and services paid for by the confiscated wealth of a diminishing number of producers. |
#12
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Soldering flexible cord (headphones)
On 12/01/13 22:49, Rick Hughes wrote:
On 12/01/2013 20:41, DrTeeth wrote: On Sat, 12 Jan 2013 16:06:52 +0000, just as I was about to take a herb, Rick Hughes disturbed my reverie and wrote: Is there a particular technique to soldering these ...... the issue is stripping the cores, it just seems to fray and get in a mess. A delicate touch is required. A sharp modeling knife/scalpel would help. -- There are a mass of wires in each core ... as I try to scrape they just all come open and stand a real risk of shorting. Wonder how they manage during manufacture crimping or a solder pot -- Ineptocracy (in-ep-toc-ra-cy) €“ a system of government where the least capable to lead are elected by the least capable of producing, and where the members of society least likely to sustain themselves or succeed, are rewarded with goods and services paid for by the confiscated wealth of a diminishing number of producers. |
#13
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Soldering flexible cord (headphones)
On Sat, 12 Jan 2013 22:15:26 +0000, newshound wrote:
On 12/01/2013 17:53, Graham. wrote: On Sat, 12 Jan 2013 16:06:52 +0000, Rick Hughes Don loads of cable soldering in the past ... but prepping the ends on this cable is proving difficult It's tinsel wire and is very difficult to deal with. What I do is to try to tin it with the iron anf hopefully melt the insulation, then find the finest strand of copper wire you can get your hands on and wind it around the end then apply a little mote solder on order to make a sort of bootlace ferrule. +1, although I have also sometimes used a tiny gas torch as another poster suggested. Another technique which used to be used on Litz wire was dipping the end in meths and setting light to it, followed by gentle scraping (but that was an enamel, not a fibrous insulation) Oh, I remember that. Winding IF transformers... -- Use the BIG mirror service in the UK: http://www.mirrorservice.org My posts (including this one) are my copyright and if @diy_forums on Twitter wish to tweet them they can pay me £30 a post *lightning surge protection* - a w_tom conductor |
#14
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Soldering flexible cord (headphones)
On Sat, 12 Jan 2013 23:53:52 +0000, The Natural Philosopher
wrote: On 12/01/13 22:47, Rick Hughes wrote: On 12/01/2013 17:48, Charles Fearnley wrote: These cables can sometimes be a bundle of thin enamelled copper wires, with the varnish in different colours for identification. That what is appears to be ... worse sometimnes it 'tinsel' which is wires interspersed with fibres good for flexcibility: almost impossible to solder at all Early telephone switchboard cords had to be highly flexible and durable. They consisted of very fine strands of tinsel (cadmium copper or bronze) spun around mercerised cotton. It was then served with layers of silk or rayon, then covered with soft cotton braiding. The only practicable way of terminating these reliably was binding the end with fine tinned copper wire formed into a loop, virtually crimping it, to attach to the screw connectors of a "jack plug", or crimping on a spade connector for the fixed end of the cord. Later cords used tiny crimped brass eyelets at the plug end. Certainly solder didn't come into it at all :-) Obviously all three conductors of the cord were then lapped in soft cotton and finished with a layer of glazed cotton of the correct colour. It all kept the cotton industry going! -- Frank Erskine |
#15
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Soldering flexible cord (headphones)
In message , Matthias Czech
writes Am 12.01.2013 17:06, schrieb Rick Hughes: [soldering problem] If that helps give an idea of cable type ...I have taken a pic: http://i771.photobucket.com/albums/x...0112_155950_zp saac86758.jpg Is there a particular technique to soldering these ...... the issue is stripping the cores, it just seems to fray and get in a mess. Just an idea (may be a bad one): Try to burn off the insulation with a pencil torch or even (if not at hand) a lighter. May work, if the insulation is cotton-based. Hope you understand, what i'm trying to say. BZW: I apologize for my bad English. I am a Kraut. Winkelschleifer ! -- geoff |
#16
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Soldering flexible cord (headphones)
On 13.01.2013 17:22, geoff wrote:
In message , Matthias Czech writes BZW: I apologize for my bad English. I am a Kraut. Winkelschleifer ! ;-) There are three things in this world that you need: Duct tape, WD-40 and Beer. Duct tape for things that move and aren't supposed to. WD-40 for things that don't move and are supposed to. And Beer if it doesn't fit into the first two categories. |
#17
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Soldering flexible cord (headphones)
In message , Matthias Czech
writes On 13.01.2013 17:22, geoff wrote: In message , Matthias Czech writes BZW: I apologize for my bad English. I am a Kraut. Winkelschleifer ! ;-) There are three things in this world that you need: Duct tape, WD-40 and Beer. Duct tape for things that move and aren't supposed to. WD-40 for things that don't move and are supposed to. And Beer if it doesn't fit into the first two categories. One wall free -- geoff |
#18
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Soldering flexible cord (headphones)
On 12/01/2013 23:54, The Natural Philosopher wrote:
Wonder how they manage during manufacture crimping or a solder pot But as it stands it is insulated ... if you crimp on it, there would not be a good connection .. they must treat the ends somehow ... and in this instance they were soldered at the plug. |
#19
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Soldering flexible cord (headphones)
In article ,
The Natural Philosopher wrote: worse sometimnes it 'tinsel' which is wires interspersed with fibres good for flexcibility: almost impossible to solder at all Normally crimped. -- *They told me I had type-A blood, but it was a Type-O.* Dave Plowman London SW To e-mail, change noise into sound. |
#20
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Soldering flexible cord (headphones)
On 13/01/2013 16:49, Matthias Czech wrote:
On 13.01.2013 17:22, geoff wrote: In message , Matthias Czech writes BZW: I apologize for my bad English. I am a Kraut. Winkelschleifer ! ;-) There are three things in this world that you need: Duct tape, WD-40 and Beer. Duct tape for things that move and aren't supposed to. WD-40 for things that don't move and are supposed to. And Beer if it doesn't fit into the first two categories. It's a standing joke here that you need a Winkelschleifer for almost anything. Andy |
#21
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Soldering flexible cord (headphones)
In message , Andy Champ
writes On 13/01/2013 16:49, Matthias Czech wrote: On 13.01.2013 17:22, geoff wrote: In message , Matthias Czech writes BZW: I apologize for my bad English. I am a Kraut. Winkelschleifer ! ;-) There are three things in this world that you need: Duct tape, WD-40 and Beer. Duct tape for things that move and aren't supposed to. WD-40 for things that don't move and are supposed to. And Beer if it doesn't fit into the first two categories. It's a standing joke here that you need a Winkelschleifer for almost anything. I think that grimly and myself originally stole it from UKRM many, ... many ... years ago but I'm going to post the above up at work -- geoff |
#22
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Soldering flexible cord (headphones)
On Sat, 12 Jan 2013 23:54:28 +0000, The Natural Philosopher
wrote: On 12/01/13 22:49, Rick Hughes wrote: On 12/01/2013 20:41, DrTeeth wrote: On Sat, 12 Jan 2013 16:06:52 +0000, just as I was about to take a herb, Rick Hughes disturbed my reverie and wrote: Is there a particular technique to soldering these ...... the issue is stripping the cores, it just seems to fray and get in a mess. A delicate touch is required. A sharp modeling knife/scalpel would help. -- There are a mass of wires in each core ... as I try to scrape they just all come open and stand a real risk of shorting. Wonder how they manage during manufacture crimping or a solder pot Does anyone remember those wiring pens we used to use for bread boarding? It dispensed what looked like 38SWG enamelled wire, but the enamel would melt as soon as you touched it with an iron. I seem to remember a warning about cyanide poisoning as well. -- Graham. %Profound_observation% |
#23
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Soldering flexible cord (headphones)
Graham. wrote:
It dispensed what looked like 38SWG enamelled wire, but the enamel would melt as soon as you touched it with an iron. I seem to remember a warning about cyanide poisoning as well. It was coated in polyurethane, hence the cyanide warning. |
#24
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Soldering flexible cord (headphones)
On Sun, 13 Jan 2013 23:22:02 +0000, Graham. wrote:
On Sat, 12 Jan 2013 23:54:28 +0000, The Natural Philosopher wrote: On 12/01/13 22:49, Rick Hughes wrote: On 12/01/2013 20:41, DrTeeth wrote: On Sat, 12 Jan 2013 16:06:52 +0000, just as I was about to take a herb, Rick Hughes disturbed my reverie and wrote: Is there a particular technique to soldering these ...... the issue is stripping the cores, it just seems to fray and get in a mess. A delicate touch is required. A sharp modeling knife/scalpel would help. -- There are a mass of wires in each core ... as I try to scrape they just all come open and stand a real risk of shorting. Wonder how they manage during manufacture crimping or a solder pot Does anyone remember those wiring pens we used to use for bread boarding? It dispensed what looked like 38SWG enamelled wire, but the enamel would melt as soon as you touched it with an iron. I seem to remember a warning about cyanide poisoning as well. http://uk.rs-online.com/web/p/products/1054626/ -- Use the BIG mirror service in the UK: http://www.mirrorservice.org My posts (including this one) are my copyright and if @diy_forums on Twitter wish to tweet them they can pay me £30 a post *lightning surge protection* - a w_tom conductor |
#25
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Soldering flexible cord (headphones)
Matthias Czech writes:
Am 12.01.2013 17:06, schrieb Rick Hughes: [soldering problem] If that helps give an idea of cable type ...I have taken a pic: http://i771.photobucket.com/albums/x...psaac86758.jpg Is there a particular technique to soldering these ...... the issue is stripping the cores, it just seems to fray and get in a mess. Just an idea (may be a bad one): Try to burn off the insulation with a pencil torch or even (if not at hand) a lighter. May work, if the insulation is cotton-based. Hope you understand, what i'm trying to say. BZW: I apologize for my bad English. I am a Kraut. That's not bad English, it's very good English. Far better than the Google-translated German I had to use last year when ordering from Germany! -- Windmill, Use t m i l l J.R.R. Tolkien:- @ O n e t e l . c o m All that is gold does not glister / Not all who wander are lost |
#26
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Soldering flexible cord (headphones)
On 13 Jan 2013 23:41:40 GMT, Bob Eager wrote:
On Sun, 13 Jan 2013 23:22:02 +0000, Graham. wrote: On Sat, 12 Jan 2013 23:54:28 +0000, The Natural Philosopher wrote: On 12/01/13 22:49, Rick Hughes wrote: On 12/01/2013 20:41, DrTeeth wrote: On Sat, 12 Jan 2013 16:06:52 +0000, just as I was about to take a herb, Rick Hughes disturbed my reverie and wrote: Is there a particular technique to soldering these ...... the issue is stripping the cores, it just seems to fray and get in a mess. A delicate touch is required. A sharp modeling knife/scalpel would help. -- There are a mass of wires in each core ... as I try to scrape they just all come open and stand a real risk of shorting. Wonder how they manage during manufacture crimping or a solder pot Does anyone remember those wiring pens we used to use for bread boarding? It dispensed what looked like 38SWG enamelled wire, but the enamel would melt as soon as you touched it with an iron. I seem to remember a warning about cyanide poisoning as well. http://uk.rs-online.com/web/p/products/1054626/ Ah Verowire 34AWG which = 37SWG. I said 38. Not bad. -- Graham. %Profound_observation% |
#27
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Soldering flexible cord (headphones)
On Sunday, January 13, 2013 1:23:52 AM UTC, Frank Erskine wrote:
snip Early telephone switchboard cords had to be highly flexible and durable. They consisted of very fine strands of tinsel (cadmium copper or bronze) spun around mercerised cotton. It was then served with layers of silk or rayon, then covered with soft cotton braiding. The only practicable way of terminating these reliably was binding the end with fine tinned copper wire formed into a loop, virtually crimping it, to attach to the screw connectors of a "jack plug", or crimping on a spade connector for the fixed end of the cord. Later cords used tiny crimped brass eyelets at the plug end. Certainly solder didn't come into it at all :-) Obviously all three conductors of the cord were then lapped in soft cotton and finished with a layer of glazed cotton of the correct colour. It all kept the cotton industry going! As I recall the plaited leads that were used with the old bakelite phones (200/300 series) were also made using tinsel. These days you can buy replacements for use when restoring phones, but most of the ones I've seen seem to be pve covered wire just given an outer braided covering - doesn't work the same way at all. |
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