Electronics > Repair

What precaution to solder those tiny gauge ? how to ?

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repairs:
HI everyone

Im new here.
I use a wheelchair and i drop the joystick from time to time.I use it unattached.That has put stress on the cable protector leading to it.
The protector opened , i put some glue on it i the past , it reopened at the same place and i was careless not to glue it again.

Now i have isolated one tiny blue wire, very close to the joystick that has broken due to the joystick being dropped and cable taking the shock. I would like to solder it back.

I did do some soldering before a bit , trial error. But that joystick cost a lot and i have very little wire space to do errors since the broken part is so close to the joystick.

What do i need to know about soldering such tiny wires? probably precautions are to take.

Also since it broke because of too much pulling on it , what is the best strategy to have a solder that will hold bending cable tension?

The 2 tiny wires dont touch or barely depending if the cable is bent or not so WOuld i be better adding 1 cm of additionnal wire to reduce tension put on the repaired wire?

thanks

i hope you can see my pictures [ Specified attachment is not available ]

Gyro:
Hi, welcome to the forum.

That's a bit of a mess isn't it. Ideally you would buy a new cable strain relief and re-terminate the entire cable inside the joystick. If you have sufficient slack in the cable, I would strongly recommend this. If there isn't enough slack in the cable, it's difficult to see how to provide enough strain relief for a lasting repair, with the other cores intact it is obviously impossible to reinforce it with layers of heatshrink sleeving.

If you have to make the repair as-is then adding a short loop of low current stranded wire will certainly get you over the problem of 'zero overlap' on the core, there's no need to make it too short. This will make it easier to make the joints away from the other cores and reduce the risk of melting their insulation. [Edit: Twist the wire strands together for secure mechanical connections that don't rely on just solder for strength, it will make soldering quicker and easier too without needing three hands]. The important thing is to work quickly to minimise wicking of solder up the strands under the insulation, this will cause the patch wire to become stiff and prone to fracture. For overall insulation, rubber self-amalgamating tape is probably the best you can do, carried up over the remains of the strain relief.

As I say, completely re-terminating the cable into the Joystick is by far the best method, if you can.

Swake:
All what Gyro already said.
'solder' is the stuff with a flux core.
Preferably you have additional separate flux to put on the wire. Flux helps a lot to make the solder 'stick' and flow in the individual cores of the wire.

Fix a rope to the joystick that is slightly shorter than the cable. When the joystick drops the rope will take the chock instead of the cable.

repairs:

--- Quote from: Gyro on January 07, 2025, 07:32:16 pm ---Hi, welcome to the forum.

That's a bit of a mess isn't it. Ideally you would buy a new cable strain relief and re-terminate the entire cable inside the joystick. If you have sufficient slack in the cable, I would strongly recommend this. If there isn't enough slack in the cable, it's difficult to see how to provide enough strain relief for a lasting repair, with the other cores intact it is obviously impossible to reinforce it with layers of heatshrink sleeving.

If you have to make the repair as-is then adding a short loop of low current stranded wire will certainly get you over the problem of 'zero overlap' on the core, there's no need to make it too short. This will make it easier to make the joints away from the other cores and reduce the risk of melting their insulation. [Edit: Twist the wire strands together for secure mechanical connections that don't rely on just solder for strength, it will make soldering quicker and easier too without needing three hands]. The important thing is to work quickly to minimise wicking of solder up the strands under the insulation, this will cause the patch wire to become stiff and prone to fracture. For overall insulation, rubber self-amalgamating tape is probably the best you can do, carried up over the remains of the strain relief.

As I say, completely re-terminating the cable into the Joystick is by far the best method, if you can.

--- End quote ---

Hi,

i have zero experience with cable strain releive. If i do a clean cut of all the wires and black cable protector, remove the tie wrap inside the joystick, will i be able to push the clean cut cable through the cable strain relief?

If not , would drilling the cable strain releif until the clean-cut cable pass through be a solution ? and add a tie wrap inside the joystick. how solid would that be?

is it worth it to buy a new cable strain releif ? how to know wich one to order? There seems to be so many. maybe it is not necessary if i add other stuff over to reinforce?

While i will have my hand in this setup is there something i can add to even make it more solid to prevent futur cable  breaking, at least at that place?

--------------
also the other option of just soldering the blue wire:
What do you think of pouring epoxy or glue or aquaseal on top of the cable strain releif until reaching the part of the cable where the black protector starts again?

Open to ideas.

THanks


2N3055:
Those strain relief ruber boots can be bought new.

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