[Milsurplus] Soldering coils...

[KD7JYK]

Find a soldering iron and tip for soldering 0603 surface mount components.
You want something with a good heat reserve.  I regularly soldered broken 36
AWG transformer windings in power transformers for telco equipment,
carefully unwinding them to the break, soldering a joint only a couple
thousandths larger than the wire, insulating and re-wrapping, then joint can
be small enough to not cause any trouble, you may have to try several times.
The iron we used was a bit pricey, it was made by Metcal, but I have seen
similar Weller units, iron and tip less than $40.  A pain in the ass to be
sure, but the iron made all the difference.  Use a good magnafier, I used a
combination 50X/100X, looked like soldering a buss bar.

Just for kicks and to see if anyone would notice in QA, I'd write my name in
script on the wire, most fun was writing on traces in AMD computer chips.

Kurt

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Ross Technologies Signals Intelligence Division
Rosetta Proving Grounds