bruce Posted January 15, 2005 Share Posted January 15, 2005 A pair of Sennheiser headphones, with a damaged jack plug. No problem, we'll just chop off the plug and solder on a new one. Should only take a couple of minutes. At least, that's the theory...... half an hour and much cursing later, the job is done. It's a "figure 8" cable, so actually 2x 2-core cables, one for each ear. Inside each of the 2 cables there are 2 stranded wires, in contact with each other. One is normal standard copper wire, the other, which is in contact with the copper, is coated in some sort of insulator. It's shiny, metallic, red in one cable, blue in the other. looks a bit like the enamel insulation you see on motor windings? First attempt: Let's just try soldering it. Maybe the heat from the iron will burn off the insulation. Answer: no, it doesn't. Second attempt: try cleaning off the enamel (?) with sandpaper. We now end up with something that resembles a poodle. There's some sort of fibre twisted in with the copper. The coloured stuff comes off, but you still can't solder it. Third attempt. Burn it off! This actually worked quite well - I could light the "wire" with a match, let it burn for a cm or two, and then blow it out when the flame got to the appropriate bit, leaving the copper which could then be soldered. It was the fibre that was burning, I think, rather than the insulation. So, what's the "proper" way of soldering this stuff?? Bruce. Link to comment Share on other sites More sharing options...
bruce Posted January 15, 2005 Author Share Posted January 15, 2005 I wrote:So, what's the "proper" way of soldering this stuff?? Bruce.<{POST_SNAPBACK}> I know it's bad practice to answer your own questions, but a "google" turned up a "Headphones FAQ" on http://www.headwize.com/faqs.htm, which answers this..... it seems that burning is the easiest option, unless you have a very hot soldering iron.... The FAQ says Why can't I splice/solder/repair headphone cords from Sony (and some other brands)? The wires in Sony headphone cords are insulated with a lacquer coating, which must be removed to make an electrical connection. Most low-wattage soldering irons are NOT hot enough to vaporize the coating. Here are some options: o Dip the wires in alcohol and ignite with a match. The ignited alcohol should burn off the insulation. (Note: I have received email that merely heating the wires with a match or cigarette lighter (without any alcohol) works equally well.) o Put the wires on an aspirin tablet and apply a soldering iron to the wire and aspirin until the aspirin melts. Aspirin is an acid that should dissolve the insulation. o Try a high voltage soldering iron if available which will burn off the insulation while soldering o Use a pocket knife to gently scrape off the insulation o Dip the wires with a lacquer solvent until the coating dissolves With any method involving a solvent, make sure there is adequate ventilation and avoid inhaling any vapors released by the process. After burning or dissolving the insulation, wipe the wires clean of any residue before soldering. Link to comment Share on other sites More sharing options...
Andrew C Posted January 15, 2005 Share Posted January 15, 2005 So, what's the "proper" way of soldering this stuff?? Bruce. <{POST_SNAPBACK}> B@stard stuff, isn't it? I have succeeded by scraping the core with a scalpel and than tinning it, but it's still not easy. To cap it all in my case I was using a plug that really didn't want to tin at all. :D Link to comment Share on other sites More sharing options...
Brian Posted January 16, 2005 Share Posted January 16, 2005 It is a bit of a pig. Option 1 is to use a good soldering iron running at the right temperature for your solder, the other is a good 'turbo' lighter. I'm always successful with option 1. Link to comment Share on other sites More sharing options...
robloxley Posted January 17, 2005 Share Posted January 17, 2005 Obviously you need to go and buy a Metcal... Link to comment Share on other sites More sharing options...
Guest lightnix Posted January 17, 2005 Share Posted January 17, 2005 Put the wires on an aspirin tablet and apply a soldering iron to the wire and aspirin until the aspirin melts. Aspirin is an acid that should dissolve the insulation.Who on earth thought that one up? :unsure: Link to comment Share on other sites More sharing options...
Light Console Posted January 18, 2005 Share Posted January 18, 2005 Hmm. Been there before too, burning was the way forward. I have seen it done on other cables too. Link to comment Share on other sites More sharing options...
AaronHorn Posted January 19, 2005 Share Posted January 19, 2005 Put the wires on an aspirin tablet and apply a soldering iron to the wire and aspirin until the aspirin melts. Aspirin is an acid that should dissolve the insulation.Who on earth thought that one up? <{POST_SNAPBACK}> Dunno, doesnt seem clever though.. Salicylic acid is a 'weak' acid and surely couldn't react enough to dissolve the coating of the wires? ALso an asprin table wouldn't be solid salicylic acid IMO. Link to comment Share on other sites More sharing options...
danburns Posted January 22, 2005 Share Posted January 22, 2005 Dunno, doesnt seem clever though.. Salicylic acid is a 'weak' acid and surely couldn't react enough to dissolve the coating of the wires? ALso an asprin table wouldn't be solid salicylic acid IMO.<{POST_SNAPBACK}> Do they make asprin chairs as well (sorry, couldn't resist) :blink: Dan Link to comment Share on other sites More sharing options...
Recommended Posts
Archived
This topic is now archived and is closed to further replies.