Topband: Soldering aluminum coax shield to copper wire
On 5/31/2020 8:56 PM, Chuck Hutton wrote: > So what is the easy reliable cheap method to get the job done? Hi Chuck I had luck with soldering copper wire to aluminum pipe using nothing more than: 1) local variety of VEGETABLE oil - you only need a few drops - used what I found in the kitchen 2) cheap fixed temperature soldering iron - mine was 40W - already head it in my junk box 3) sand paper - I used what I hand on hand - mine was "120" grit - already had it in my junk box 4) conventional resin core solder 60/40 - already had it in my junk box The copper wire jumpers that I have soldered to an aluminum pipe (that was part of RX loop experiments - LZ1AQ variety of loops) a year and a half ago, as inspected today looks perfectly "healthy" with no signs of corrosion etc. so I assume the method has worked. Before attempting to solder I watched several YouTube videos to see how others done it. In the process, I have applied a couple of drops on top of the aluminum surface and then rubbed it slightly with the sand paper. The surface was left covered in oil. I have then separately pre-soldered the copper wire (multi-strand wire in my case) using the 60/40 solder having it sub-merged in a couple of drops of oil. Then placed the pre-soldered wire to the aluminum surface that was previously cleaned and still covered in oil. Applied another drop of oil. Placed the soldering iron on the join, and pretty much instantaneously removed it. This method has worked for me; I tried this on different aluminum surfaces and learned that in my case it was all about careful cleaning sub-merged in oil, and applying the right level of heat for the right duration of time. Good luck! Tomas VK2CCC _ Searchable Archives: http://www.contesting.com/_topband - Topband Reflector
Re: Topband: Soldering aluminum coax shield to copper wire
Hi All Try https://uk.farnell.com/multicore-loctite/629443/solder-wire-80-18-2-0-91mm-500g/dp/629443?CMP=KNC-GUK-GEN-KWL-MAN-L5Pages-New-Structure-25May2020-LOCTITE&mckv=_dc|pcrid|437370420948|&gclid=EAIaIQobChMIsZbSq_Hi6QIVCLrtCh3EzwKgEAAYASAAEgIpjvD_BwE# This is from a UK supplier but they are part of the AVNET group of which Newark is/was also one of their companies. Expensive but you may be able to get smaller reels Regards David G4FTC From: Topband on behalf of Chuck Hutton Sent: 01 June 2020 03:56 To: topband@contesting.com Subject: Topband: Soldering aluminum coax shield to copper wire Many many years ago I had partial success soldering aluminum coax shield to copper wire using the motor oil technique. I also believe I had some flux (unknown type) that helped. But I had no luck with motor oil last week and can not find the flux I had, which might be a good thing as it is 20 years old. So what is the easy reliable cheap method to get the job done? Chuck _ Searchable Archives: http://www.contesting.com/_topband - Topband Reflector _ Searchable Archives: http://www.contesting.com/_topband - Topband Reflector
Re: Topband: Soldering aluminum coax shield to copper wire
On 6/1/2020 8:11 PM, Jim Brown wrote: On 6/1/2020 7:42 PM, Chuck Hutton wrote: I wish to solder copper wire to the shield. I understand the question, but since you've so far received no responses, I wanted to point out what "the industry" and other hams have done. 73, Jim K9YC OK, I'll give a response: At the 2014 Dayton Hamvention, there was a guy selling what was marked: "Low Temperature Aluminum Repair Rod." I purchased a few dozen rods, but never used them. They came with a very detailed instruction sheet that said they could be mail ordered from the guy at this address: Robert Dunbar 453679 Creek Avenue Afton, OK 74331 I checked QRZ, and he doesn't appear to be any of the 7 "Robert Dunbar" hams on QRZ. You could invest 55 cents and mail to the address I showed. BTW, the instructions specifically recommended against your motor oil method. Instead, the work piece must be degreased. I also googled "Low Temperature Aluminum Repair Rod" and the first hit produced: aluminumrepair.com This site seems to be the motherlode for this stuff. They certainly talk a good game, just like the guy at Dayton did. The site owner is "New Technology Products" in Houston, FWIW. If you try these out, post your results, good or bad, on this reflector. Good luck! Rick N6RK _ Searchable Archives: http://www.contesting.com/_topband - Topband Reflector
Re: Topband: Soldering aluminum coax shield to copper wire
Given the thickness of the foil and the likely surface treatment, I think soldering is going to be difficult. I've watched a TIG welding genius butt weld Coors aluminum cans (<0.004" thick) together. That might work. Maybe a spot weld ala a Si chip wire bonder. Grant KZ1W On 6/1/2020 19:42, Chuck Hutton wrote: Jim - Thanks. Of course one can use crimp connectors. There a zillions of those in common use. But that was not the question. I wish to solder copper wire to the shield. Chuck From: Topband on behalf of Jim Brown Sent: Monday, June 1, 2020 7:20 PM To: topband@contesting.com Subject: Re: Topband: Soldering aluminum coax shield to copper wire On 5/31/2020 8:56 PM, Chuck Hutton wrote: So what is the easy reliable cheap method to get the job done? The only methods I know of are some form of crimp. Many variations of RG6 and RG11 with Al shields are widely used in the CATV industry. "SnapNSeal" is a widely used brand of Type F connectors that come in different physical sizes to fit those different cables, and there are crimpers to go with them. I've used these RG6 cables for receive antennas for more than 40 years. On one of my gigs almost 50 years ago, I installed a lot of MATV outlets in Sears Tower and in apartment buildings on Lake Shore Drive when they were under construction. The only Al shielded cable I'm using for transmitting is some vintage 1/2-in CATV hard line that I inherited from a neighbor SK. That hard line has Cu-clad Al center and Al shield. I'm using sections of it for parts of the run to two mono-banders. There are photos and text of page 6 of http://k9yc.com/Coax-Stubs.pdf showing the method I used. Where I used braid, other hams have slit copper tubing in half lengthwise, and are also listed on that page. 73, Jim K9YC _ Searchable Archives: http://www.contesting.com/_topband - Topband Reflector _ Searchable Archives: http://www.contesting.com/_topband - Topband Reflector _ Searchable Archives: http://www.contesting.com/_topband - Topband Reflector
Re: Topband: Soldering aluminum coax shield to copper wire
On 6/1/2020 7:42 PM, Chuck Hutton wrote: I wish to solder copper wire to the shield. I understand the question, but since you've so far received no responses, I wanted to point out what "the industry" and other hams have done. 73, Jim K9YC _ Searchable Archives: http://www.contesting.com/_topband - Topband Reflector
Re: Topband: Soldering aluminum coax shield to copper wire
Jim - Thanks. Of course one can use crimp connectors. There a zillions of those in common use. But that was not the question. I wish to solder copper wire to the shield. Chuck From: Topband on behalf of Jim Brown Sent: Monday, June 1, 2020 7:20 PM To: topband@contesting.com Subject: Re: Topband: Soldering aluminum coax shield to copper wire On 5/31/2020 8:56 PM, Chuck Hutton wrote: > So what is the easy reliable cheap method to get the job done? The only methods I know of are some form of crimp. Many variations of RG6 and RG11 with Al shields are widely used in the CATV industry. "SnapNSeal" is a widely used brand of Type F connectors that come in different physical sizes to fit those different cables, and there are crimpers to go with them. I've used these RG6 cables for receive antennas for more than 40 years. On one of my gigs almost 50 years ago, I installed a lot of MATV outlets in Sears Tower and in apartment buildings on Lake Shore Drive when they were under construction. The only Al shielded cable I'm using for transmitting is some vintage 1/2-in CATV hard line that I inherited from a neighbor SK. That hard line has Cu-clad Al center and Al shield. I'm using sections of it for parts of the run to two mono-banders. There are photos and text of page 6 of http://k9yc.com/Coax-Stubs.pdf showing the method I used. Where I used braid, other hams have slit copper tubing in half lengthwise, and are also listed on that page. 73, Jim K9YC _ Searchable Archives: http://www.contesting.com/_topband - Topband Reflector _ Searchable Archives: http://www.contesting.com/_topband - Topband Reflector
Re: Topband: Soldering aluminum coax shield to copper wire
On 5/31/2020 8:56 PM, Chuck Hutton wrote: So what is the easy reliable cheap method to get the job done? The only methods I know of are some form of crimp. Many variations of RG6 and RG11 with Al shields are widely used in the CATV industry. "SnapNSeal" is a widely used brand of Type F connectors that come in different physical sizes to fit those different cables, and there are crimpers to go with them. I've used these RG6 cables for receive antennas for more than 40 years. On one of my gigs almost 50 years ago, I installed a lot of MATV outlets in Sears Tower and in apartment buildings on Lake Shore Drive when they were under construction. The only Al shielded cable I'm using for transmitting is some vintage 1/2-in CATV hard line that I inherited from a neighbor SK. That hard line has Cu-clad Al center and Al shield. I'm using sections of it for parts of the run to two mono-banders. There are photos and text of page 6 of http://k9yc.com/Coax-Stubs.pdf showing the method I used. Where I used braid, other hams have slit copper tubing in half lengthwise, and are also listed on that page. 73, Jim K9YC _ Searchable Archives: http://www.contesting.com/_topband - Topband Reflector
Topband: Soldering aluminum coax shield to copper wire
Many many years ago I had partial success soldering aluminum coax shield to copper wire using the motor oil technique. I also believe I had some flux (unknown type) that helped. But I had no luck with motor oil last week and can not find the flux I had, which might be a good thing as it is 20 years old. So what is the easy reliable cheap method to get the job done? Chuck _ Searchable Archives: http://www.contesting.com/_topband - Topband Reflector
