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Guru

Join Date: Apr 2007
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Male Mini-DIN Soldering Issue

05/19/2010 10:04 PM

Hi there, I have to re-solder the cables from an extension cord of my bike´s intercom headset to a new male (6 pole) mini-DIN plug. I disassembled the enclosure of the plug until exposing a 8mm dia round plastic into which the 6 pins are inserted to. On one side are the male pins and a square larger centering pin. These are to be connected the female plug. On the opposite side, pins get thicker (where I expected to see a hole, to solder the cables into). To my dissapointment the pins on this side were flat, so I supposed the hole was filled with soldering material that had to be heated with the soldering iron having only to slip the bare cable into it. I tried by all means to heat the back of each pin up to do so, but only managed to melt the pins loose from the plastic disc, No need to say how disappointed I am: just supposed I would do this repair in 5 minutes and spent 1 hour only managing to ruin the plug!!!! The only alternative I thought of was that there must be a small crimping device or a female part to solder the wires to be connected to these f****k pins. Any clue?????

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#1

Re: Male Mini-DIN Soldering Issue

05/19/2010 10:44 PM

Don't know the specific plug you are talking of, but it sounds like the flat surface you described is the area that you would solder the wires onto.

This reminds me of my nemesis in soldering. The job that needed four hands to do. One to hold the tiny workpiece, one to hold the iron, one to hold the solder and one to hold the wire.

Suggest hold the connector in a blob of "blu-tack" on the bench, then with a VERY hot iron and very short soldering times, tin/solder all the wire ends, tin/solder all the terminal ends (then put down the solder) then bond the wires to the relevant terminal with no additional solder. (While not ideal manufacturing practice, for a one off home job it will be adequate.)

The use of the VERY hot iron means that soldering times can be significantly reduced, you're only soldering wire and terminals so no chance to roast electronics bits and the heat transfer time will less likely affect the wire insulation or the connector.

Remember that the wire joints are NOT meant to cary the strain of the cable. Otherwise, the shortest wire will cary all the strain and break, then the next shortest and so on.

Have fun!!!!

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Guru

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#2
In reply to #1

Re: Male Mini-DIN Soldering Issue

05/20/2010 3:13 AM

I agree about using a VERY hot iron; I started with a 40 W one, as time was to lonng, jumped to 60 and finally to 150W, You are right, this job needs at least 4 hands, so I held the plastic isolator with the pins on it on a vice. I did tin the wires,,,, but not the terminals.... (that might have been my mistake). Thanks for the idea, I´ll try it out tomorrow!

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#3
In reply to #2

Re: Male Mini-DIN Soldering Issue

05/20/2010 8:35 PM

If a 25 Watt doesn't do the job, you'll need to clean the contacts first and get a fine point soldering iron. Go also for the thin 50/50 lead- tin solder with flux inside. You should warm up the pin ends to about 200 a 250 degrees Celsius and then add the tin, pointing it against the tip of the iron, that has contact with the pin, Just let a small amount of the tin melt to the point and use that to make a better heat contact with the pin. You should add tin solder to the pin, otherwise you risk a "cold" solder point. You might be working easier fixing the plug to have more play with you fingers. I always did it in the hand, but I probably soldered hundreds of them. Let your iron warm up first and work with a lot of light. If you have dropped solder that connect 2 pin, you clean your tip an collect some on it or use a stranded string of fine copper or tinned wire to suck it up when you heat it with your iron. A fine tip and clean carbon free tip is what you need.

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Guru

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#4

Re: Male Mini-DIN Soldering Issue

05/21/2010 10:04 AM

EUREKA! Based on trial and error + your tips, I finally got a decent job done: the aid of a "primer" (contacts cleaning acid) and a better solderer (220V / 60W) was the clue to it. First, I dipped both the nude end of the cable and the back of the pins in the primer for some sec´s. To prevent movement, I constrained the DIN socket in a bench vise. With the aid of a magnifying glass with light each part to be soldered was heated up in sequence, to place a drop tin on each. Then I slightly pressed the tip of the cable against the corresponding terminal and heated both parts wit the tip of the iron. parts got properly soldered when tin acquired a silvery shine. Thanks to you all

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#5
In reply to #4

Re: Male Mini-DIN Soldering Issue

05/21/2010 12:08 PM

Since the job is already done, it's probably too late to remind you not to use acid flux. But, it is not too late to suggest that you flush the connections with lots of water. Your acid flux will, over time, make the wires go away. Good luck.

I have not yet met the hobbyist who likes to solder DIN connectors.

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#6

Re: Male Mini-DIN Soldering Issue

05/21/2010 2:31 PM

My GA to Just and the previous to this about using acid flux in electrica soldering. Also too late, as I always do to used heat shrink tubing over each connection. Makes a big difference in longevity of any given connection.

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