*EXPERT LEVEL* Soldering Tutorial #3 TTC Avionics

all right we're now going to take a wire and connect it to a hook terminal so we'll have deadly start us out the steps all right step one be insert our terminal into a phenolic block all right done step one C clean the terminal all right so I'm going to take my alcohol lightly clean the terminal and then add my flux step one II clean the iron when I clean the iron solder is removed I'm gonna remove the oxidation okay step one F tin the terminal tin the terminal lightly tin the iron first create a solder bridge put the back of the terminal ad from the front end it comes back and it's ten step one G place the solder wick on the solder right now solder from the terminal alright so now I need to remove the any excess solder that happens to be on the terminal doesn't look like there's a lot there up we're going to give this a shot I'm going to take the solder wick add flux lightly flux the solder wick you have a nice little layer and then in order to remove this what I need to do is add solder from the iron to the wick to form a bridge and then add that to the terminal itself so I'm not I'm going to lightly clean my iron I'm now going to add solder solder to my soldering iron and then I'm going to add this solder to the wick itself and finally this solder will make a bridge and I just wipe it around just like you would wipe the table with a wet cloth and you can see that it removed any excess solder OOP I got a tin my iron before I place it in the holder removed any excess solder the solder excess solder is now on the solder wick and that should be solder free step one H clean the tin terminal I'm gonna clean it in terminal by taking my stiff bristle brush and my chem wipe so I don't make a mess and just lightly scrub the hook terminal okay step one I place the wire up against the bottom of the hub all right that wire that we pretend in the previous step our previous subject I'm going to take it and I'm going to place it up that 10 wire place it up against the terminal okay step one J wrap the wire tightly around the terminal the insulation shall not be embedded in the solder joint and shall be less than two wire diameters including insulation so what they mean there is my insulation I do not want this embedded or touching the top of the hook terminal however I also don't want to have excess wire sticking out away from the terminal so I can I cannot touch it nor can I be more than two wire lengths away if I take a wire including the insulation if I double it up double it up and place it against the terminal I can see that's a pretty good distance so I'm going to use a single strand to get me right in between to give me a good guide of how far I need to be away from that hook terminal I hold that wire wire including the insulation up against the terminal and now I'm going to form and bet our Ben around the terminal now these needlenose do not have any teeth so it's not meant doing any damage to the terminal all right next epidemic step 1k slide the wire off the terminal let's cut the bent wire so that it will only make contact with the terminal for a half time to three-quarters time okay what Dudley is saying is that now that I have my wire bent around my terminal I'm going to bend and I don't want to I want to be either halfway around the terminal to three quarters of the way right now I'm halfway so I'm going to bend a little bit further before I slide the terminal law between 1/2 and 3/4 and the slide off the terminal then you can see that my you can see my connection now when I look here though I want to know how much is cut I don't want to cut on to the terminal because I'm a nick or damaged the hook terminal but I do want to grab it lightly so I know where to cut I'll slide it off and now I'm simply going to cut okay step 1 I'll hold the cut wire against the terminal to check the wrap dimension the wires shall contact the terminal for the full turn for which it is cut and we cut the end of the wire is necessary all right so I'm looking at my terminal and I want to just read because as I cut it it can bend so I just want to hit it up and reform it around the terminal if need be you can hold it in place and just kind of bend the wire around the terminal hold it in place and then and just making sure it's all the way up against my termer okay all right now we're going to position the wire attach the wire from the terminal to the spring which will hold it during the soldering all right so now I'm bringing my spring over to hold my wire whoops there we go my spring and try to get it the hole over the top of my terminal and ideally I have it straight up and down so in this case I need to come up and bend it over if possible there we go nice arc I'm going to check it again looking to see that it's straight up and down grabbing the terminal again forming it and then making sure mechanically it is connected all the way around the hook terminal which it all right now we're going to clean the connection so without disturbing your connection I'm going to lightly clean the hook and the wire together then I'm going to add flux to the entire package okay next we're going to cut the end of the solder alright so now I need to tick my solder cut a piece off don't burn it off don't Carter eyes it need that core to be exposed so you can add the fuck's that's inside Sauder I'm going to clean clean my solder with my my fin alcohol next we're going to cut the end of the solder okay and then we're going to clean the soldering iron all right now I'm going to go through putting the iron remove the oxidation right then we're going to position the iron and then apply solder all right so now a clean oxidation you can remember you only have a few seconds before the oxidation begins to form or yellow on the iron so I want to keep removing it but what I want to show you here is I want to take this solder and I want to form a heat bridge between the hook terminal and the wire itself so I'm going to clean it because I began to yellow now I'm going to tin and then create a bridge create a bridge between the two and now once you have the heat transfer I can add solder to each end of the hook and to the wire and then simply remove remove the solder first and then hold for a second and then remove the iron don't forget to retain the wire or the iron before placing it back in the holder and lastly we're going to clean the connection all right so now I want to clean the connection I'm gonna take a chem wipe and then take solder on to a stiff bristle brush place this so you don't make a mess you place it and wipe this the flux off onto the chem wipe and you got to use that stiff bristle brush because sometimes the flux likes to accumulate it into the little joints now when I was adding solder after forming the bridge I added again I added the wire to each end of the terminal and the end of the wire it's going to flow toward the iron itself and I cover any exposed copper any exposed copper around the hook terminal any exposed copper on the wire which there shouldn't be from tinning and then you don't want to add too much you just want a nice fill it between the wire itself and the hook terminal we're going to inspect it smoothly try to get this out of here out of the phenolic block I have flux that ran down so I'm going to have to clean the bottom here clean the bottom and then I'm looking at my connection I know if you can see that mm-hmm look at my connection and making sure that I have the pull wire attached to the hook terminal 1/2 to 3/4 all the way around the hook a nice fillit not excess solder you don't want a big glob I want to see the outline of the wire and I want to see the outline of the hook throughout the entire connection which I do and then again and not a big glob and long as you can see the outline that is a good solder joint and no exposed copper and no and you don't know no flux that's embedded into the end of the wire also you want to make sure that the wire the solder didn't wake up into the wire which it didn't so it's a nice flexible joint right here at the end in a complete connection on both sides and it's very shiny shiny tells you that it wasn't overheated it didn't move while you were soldering and that's

Channel: michael hobson

Views: 85,298

Rating: 4.2376876 out of 5

Keywords: expert, electronics, diy, do, it, yourself, skunkworks, aurora, area, 51, top, secret, exclusive, nasa, soldering, tutorial, trident, technical, college, ttc, avionics, mike, bunting, j-hook, solder, howto, how, to, how-to, boeing, charleston, sc, south, carolina, relay, repair, wiring, connector

Id: zusJSKeXGHE

Length: 12min 23sec (743 seconds)

Published: Wed Jan 11 2012

Reddit Comments

[u/t_Lancer]

this has nothing to do with government. it's aerospace. How would you like to sit in a plane that has bad solder joints?

[u/RadioHacktive]

I worked in Avionics a few years, in production. They are very particular about this stuff because lives can depend on it. Also they have historical data that proves the efficacy of doing things their way. Consumer electronics is pure crap when it comes to soldering. And in many other categories as well.

[u/valhallaswyrdo]

I was an avionics tech for 6 years I may have just a little insight that could help here. The instructional manuals that he is teaching from are designed and written to be followed step by step in a fashion that even a child could understand. In fact they are written on a fourth grade level. This is to ensure quality EVERY time, because this is not a toy this is a vehicle that human lives are depending on to work absolutely without fail. The steps may seem outrageous, and in all fairness they may actually be just that but be honest with yourself for a moment here: do you want to ride on a plane across the ocean that was worked on by someone with this meticulous attention to detail or are you ok with one that has been macguyver'd together with duct tape?

[u/Meltz014]

Money shot at 9:35

[u/riyadhelalami]

Very informative, a lot to learn from.