Wire Splicing and Soldering X178
Tools, Material, Equipment:
2 pieces of wire 4 inches long
Wire Stripper
Soldering Iron/Gun
Rosen Core Solder
Flux Paste
Electrical Tape
References:
Auto Mechanics Fundamentals, page 443.
X178 Wire Splicing and Soldering Booklet
Procedure:
1. Strip about 1 inch of insulation from each of the wire ends. Be sure to use proper size of cutters on wire strippers.
2. Clean of all dirt and oxidation from the bare wire with emery cloth or sand paper.
3. Make a Western Union Joint as shown in figures 1, 2, and 3. Make the wraps as tight as possible to ensure a strong, conductive connection before soldering.
4. Have your instructor check the connection.
5. Apply the soldering iron to heat the connections as shown in figure 4. Do not overheat the wires or the insulation may be melted or burned.
6. Apply the rosin core solder to the wire opposite the soldering copper. When the heat has penetrated, the solder will melt and flow through the joint leaving a smooth finish.
7. The solder should cover just beyond the last wrap of wire, but should not be next to the insulation.
8. Allow the connection to cool and wipe the joint clean.
9. Check with your instructor and get electrical tape if the connection is approved.
10. When taping the wire, start in the centre of the joint, with the tape at about 60 degrees to the wire.
11. Holding the wire and tape firmly, slightly stretch the tape and begin wrapping it around the joint. Each wrap should lap the previous wrap by about one-half.
12. Wrap to about 1 inch beyond the bare wire, and begin to reverse direction by firmly pulling the tape to 90 degrees to the wire, then to about 60 degrees to the other end of the wire.
13. Now wrap over what you have been done. Continue wrapping until you have wrapped 1inch of the other end on insulation, reverse your direction and tightly wrap to about 1 inch past your starting point.
14. Show your instructor.
Check Point ______
15. Next, cut the loop of wire you have made opposite of the joint you just completed.
16. Follow steps 1 through 8 and create another Western Union solder joint. However, instead of electrical tape – ask your instructor for some heat shrink tubing and complete the joint with that.
17. Show your instructor
Check Point ______1.0 Hrs