Date:         Thu, 2 Nov 2000 11:59:46 -0500
Reply-To:     David Beierl <dbeierl@ATTGLOBAL.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         David Beierl <dbeierl@ATTGLOBAL.NET>
Subject:      Re: Headlight improvements ?
Comments: To: "Filcoff, David M." <FilcoffD@MISSOURI.EDU>
In-Reply-To:  <7C63391505B75E449AEABF39791E44E3076979A5@umc-mail02.missou
              ri.edu>
Content-Type: text/plain; charset="us-ascii"; format=flowed

At 11:09 11/2/2000, Filcoff, David M. wrote:
>First, it is more difficult to get a consistently good solder joint.  Second
>a *good* crimp is generally stronger than a solder joint.  Note that these

Haven't seen any mention yet of one of the necessities of a good crimp
joint, which is a proper calibrated crimp tool that won't release until the
correct pressure is applied.  Mine cost about $60, import brand.

As to strength, solder joints as such have virtually no strength
long-term.  A solder joint needs to be mechanically secure before the
solder goes in.  Also as has been pointed out, solder wicking into the
stranded wire makes it inflexible and subject to fatigue failure.  There
are special beryllium-copper anti-wicking tweezers available for $$ which
will prevent the solder from reaching back under the insulation of the
wire...or the joint can be mechanically supported back to where it becomes
flexible again.

"Marine grade" crimp fasteners are available which are enclosed in
shrink-tubing with a sticky filler on the inside, to seal a joint against
the atmosphere.  Also marine-grade wire which 1) has a large number of
strands and 2) each strand is individually tinned.

david
David Beierl - Providence, RI
  http://pws.prserv.net/synergy/Vanagon/
'84 Westy "Dutiful Passage"
'85 GL "Poor Relation"