[TowerTalk] Hardware Question

[Mahlon Haunschild]

Tom,

Wussy irons like you describe will do what you describe:  melt the cable 
without making a good solder connection to the connector.  I used to use 
a Weller 200/240-watt soldering gun for PL-259 shells, but not even that 
beast put out enough heat.  These days I use a butane mini-torch.  Much 
lighter and therefore easier to control.

More heat is better than less in this case, at least in my experience. 
The idea is to get the "hole area" of the connector hot enough quickly 
enough so that you can solder the braid to the connector shell quickly 
enough that the jacket/dielectric (esp. foam dielectric) doesn't have 
enough time to melt.  Use a mini-vise to hold the cable to position the 
connector so you can solder two holes with one set-up.

OK, you caught me at a weak moment:  here follows my mystical PL-259 
installation procedure, developed painstakingly over a LONG period of 
time:   Strip jacket/braid/dielectric CORRECTLY.  Flux the braid with a 
small amount of GOOD flux (not that Rat Shack crap; I use strain gauge 
flux).  Tin the braid with a soldering iron; use only enough solder to 
do the job, excess will prevent installation of the connector.  Cool the 
cable/braid w/damp rag.  Double-check the end to ensure that no stray 
braid strands are where they shouldn't be.  Flux the braid again.  Screw 
connector onto cable.  Place connector into vise with the cable wound up 
1/2 turn.  Heat w/torch and solder holes 1 & 2.  Release vise; the cable 
will by itself position for holes 3 & 4.  Heat w/torch and solder holes 
3 and 4.  IMMEDIATELY quench the connector with the damp rag.

Using this method, I have not had a connector failure in something like 
18 years.

5 cents, please.  I accept PayPal.

Oh, by the way: results not guaranteed on vinyl cable jackets (but 
surely you don't have any of that, do you?).

regards,

Mahlon - K4OQ

Tom Anderson wrote:
> Fellow Tower Talkians:
> 
> Any suggestions for a high wattage soldering iron good for using on 
> PL259s (100 watts or so??)?   Most of the 25-40 watt irons found in the 
> mass hardware places (Home Depot/Lowes) seem to melt more die-electric 
> than solder.  Anyone use/have any luck with opne of those Sears  100/400 
> watt soldering gun?
> 
> Tom, WW5L