To splice wire for soldering, you essentially expose the conductive core of both wires and then mechanically join them before applying solder to create a permanent, electrically sound connection. Here's a breakdown of the process:
1. Preparing the Wires:
- Strip the Insulation: Carefully remove the insulation from the ends of the wires you wish to join. The amount of insulation you strip back will depend on the type of splice you are making, but generally, about 1/2 to 1 inch is sufficient. Use wire strippers appropriate for the gauge (thickness) of the wire to avoid nicking or damaging the conductive core. Damaged wires can weaken the splice.
- Clean the Conductors: Ensure the exposed copper or other conductive material is clean and free of any oxidation or dirt. You can use a wire brush or fine-grit sandpaper to gently clean the conductors. This ensures a good solder joint.
2. Joining the Wires (Example: Western Union Splice):
The Western Union Splice is a common and reliable method for splicing wires:
- Overlap the Wires: Position the two wires so that their exposed conductive sections overlap each other.
- Wrap the Wires: Wrap each wire tightly around the other's conductor. Make at least 4-5 tight wraps on each side. This creates a strong mechanical connection. The tighter the wraps, the better the electrical connection before soldering.
- Ensure Contact: Make sure the wraps are tight and make good contact with each other. This is crucial for a strong and low-resistance electrical connection.
3. Soldering the Splice:
- Heat the Joint: Use a soldering iron to heat the entire spliced joint. The goal is to heat the wires themselves, not just the solder.
- Apply Solder: Once the wires are hot enough, touch the solder to the heated wires. The solder should melt and flow smoothly around the joint, filling any gaps and creating a solid connection. Don't apply too much solder; you want a smooth, even coating.
- Let it Cool: Allow the solder joint to cool naturally. Avoid blowing on it or moving the wires while it's cooling, as this can weaken the joint.
4. Insulating the Splice:
- Apply Insulation: Cover the soldered joint with electrical tape, heat shrink tubing, or liquid electrical tape to insulate it and prevent short circuits. Heat shrink tubing is generally preferred for its durability and professional finish. If using heat shrink, slide it over one of the wires before making the splice.
Important Considerations:
- Wire Gauge: Use appropriate gauge wire for the intended application. Splicing wires of different gauges can be problematic.
- Solder Type: Use rosin-core solder intended for electrical work. Acid-core solder is corrosive and should not be used for electronics.
- Safety: Wear safety glasses to protect your eyes from solder splatter and work in a well-ventilated area to avoid inhaling solder fumes.
- Practice: Splicing wire for soldering takes practice. Don't be discouraged if your first few attempts aren't perfect.
Alternatives Splice Methods:
While the Western Union Splice is a popular choice, other splice methods exist, including:
- Lineman's Splice: Used for larger gauge wires.
- Staggered Splice: Used when space is limited.
Regardless of the method chosen, always ensure a strong mechanical connection before soldering.
