DB-1 Ep. 14 Aviation Connector Soldering
Bill mentioned in Ep. 14 difficulty in soldering six conductor cable to the aviation connectors. I came up with a reasonably easy way to make neat solder connections. I used clear butt connectors and a hot air gun with a 5mm diameter nozzle. For those who don't know what a butt connector is just search the name. It is a shrink tube with a solder ring installed inside.
METHOD - Remove 1/2" of insulation from 24 AWG, 6 conductor cable. Bend all but one wire out of the way. Strip 1/8" off the end of the remaining wire, the one intended for the center pin (#6), color is your choice. Just remember the color sequence when you finish your first connector so you can duplicate the pattern on subsequent assemblies. Trim a butt connector so that the solder ring is centered with about 3.5mm of tubing on either end. Slip the butt connector over the wire, position the wire on the pin and slide the butt connector over the wire and pin. This captures the wire and aligns the solder ring on the joint. Using the heat gun, apply heat until the tubing shrinks and the solder flows creating a insulated, neat solder joint. Repeat the process for each wire, one at a time. Finish by sliding a length of shrink tubing over the cable and connector pins. Run a couple of tests on plain wire to set the heat gun to the correct temperature before attempting to solder the cable to a connector.
Could you post a photo? This sounds interesting.
I had difficulty posting pics. That is why the long description. I trashed my laptop a few days ago trying to set up a Linux partition. Just got a new laptop so I'm back in business. Will try to post pics again. My email is firstname.lastname@example.org. Send a request and I will send pics of the process.
In a reply post you will see Choose a files or drag and drop it here.
Click on Choose a files.
A window will pop up.
Click [Attach Files]
Select the image you want from your computer and once loaded making sure the box on the right is selected click,
[Insert Into Post]
I thought I had a problem with file size so I sent a pic to my email account as a small size pic. I will try again attaching it to this reply. Let's see what happens.
Problem solved. I saved the pic as small and I was able to attach it. The pic shows the nozzle from the heat gun pointing at the last solder joint. Notice how neat all the connections are.
I really appreciate your taking the time to post these excellent pictures. It gives me a better idea of what I am aiming for. I have ordered the butt connectors and I will give this a try when they arrive.
You're welcome. One thing I forgot to mention was what to do with the ground wire. I slit the outer sheath length wise about 1/2" and pulled the ground wire out. This provides enough length to make a ground connection to the DB-1 frame. The Actobotics channel has a protective coating on it so scratch the surface to ensure the ground wire makes good contact. Make the final shrink tube length equal to the distance from the connector body to the ground lead where it exits the sheath. Attached is a pic of the connector assembly installed in DB-1.
How u doin? Did you get the necessary supplies to try my method for making aviation connector cable assemblies? I hope it worked for you.
What size cable were you using for the aircraft connectors. I found some Belden 9536 at wireandcableyourway.com that was 24AWG that looked like it included a drain wire. I seem to have plenty of multi-conductor cable around here, but no 6 conductor!
Also where did you get the solder type butt connectors. So far everything I've come across seems way to big. I saw an assortment on Amazon that included some foe 24AWG wire but they looked like they were way too long.
Check out the link below for the butt connectors. I trimmed the length to fit the connectors. I posted written instructions in one post and posted a couple of pics in another post. Will send you a link for the cable soon.
I found the cable on ebay in 25' lengths.