[R-390] Filter Repair

[Charles P. Steinmetz]

Dave wrote:

>I need help with connecting #40 wire together.  When I do it, I loop 
>each end, try to crush them on each other, solder them and then glue 
>them with epoxy for insulation and stability.

All you can do by trying to "crush them on each other" is deform the 
wire and create weak spots that will be prone to future 
breakage.  Ideally, you would hold the two uninsulated ends precisely 
parallel and touching, overlapping by the length the ends have been 
stripped, and solder them.  Like this:

   ===============------
                   ------===============

Use a monospaced font to view the ASCII graphic.  "====" represents 
wire with the insulation still on, "----" represents the wire ends 
that have been stripped.  You would move the upper wire down until 
its bare end is touching the bare end of the lower wire, then solder 
them.  Use enamel (fingernail polish works) or glue to insulate the joint.

If you are stripping the enamel by scraping, be extremely careful not 
to nick the wires.  Better to use a solder pot to remove the 
insulation and tin the ends of the wires.

Best regards,

Charles