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Old Aug 26, 2003, 02:49 PM
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How to solder a Deans Ultra connector


This is buried in another thread. For benefit of those not participating there, I'm posting a new thread.

http://www.ezonemag.com/~awilletts/deansultra.mpg

Feedback appreciated - I had the wires reversed last time!
New lighting, removed music (copyright), etc.
..a
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Old Aug 26, 2003, 02:55 PM
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looks good Andy
Old Aug 26, 2003, 03:34 PM
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Thank you! I was struggling with soldering the connectors earlier (took a break because the iron slipped back and burned a finger just behind the nail). Now I will give it another go, hopefully more successfully!

Brian
Old Aug 26, 2003, 03:52 PM
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Another little trick to helps minimize damage is to plug the connector into its mating end. Helps maintain alignment and reduce potential distortion of the plastic and movement of the contacts.
Old Aug 26, 2003, 04:27 PM
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This can actually cause distortion, according to some. I have never experienced that problem, and there's not enough heat or time the way I show it being done for any deformation to be a problem..
..a
Old Aug 26, 2003, 05:15 PM
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Why, because of the pressure from the mating contacts?
Old Aug 26, 2003, 05:15 PM
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Nice one andy

phil
Old Aug 26, 2003, 06:24 PM
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Very nice Andy.

I must admit when I saw the part where you clamped the connector down I was expecting to see it go zinging across the workbench...not that it's ever happened to me

Using a hot iron with a big tip really makes the difference in soldering large conductors and contacts and in the case of the Ultras, makes all the difference in the world in getting a good clean connection.

Distortion of the plastic housing is a problem if you keep an iron on the contact too long during soldering. Sometimes, when mated, the connectors have an unbalanced stress (one contact is pushed in just a wee bit more than the other) and during soldering, could shift because of this.

Ensuring you heat up the conductor first then the contact as in Andy's video will help to minimize this problem. Now if you heat up the conductor too much, your heatshrink will be pre-shrunk!

Regards,
Roger
Old Aug 26, 2003, 07:04 PM
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The point to my video is to show 'how quick and simple' it is. I should do another showing them being unplugged, right?
.a.
Old Aug 26, 2003, 08:08 PM
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Actually now that you mention it, I saw a fellow flyer recently who drilled a small hole between each conductor and installed small pulling loops with 20 lb monofilament. Pretty idea!

Roger
Old Nov 06, 2003, 05:52 AM
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I have a Q what can you use to heat up the heat shrink i have no clue
Old Nov 06, 2003, 06:49 AM
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Heat gun - same as used to shrink covering.
If you don't have one, you can hold a lighter a couple of inches below, but I suggest you practice a lot first so you don't burn the shrink or connector!
..a
Old Nov 06, 2003, 06:53 AM
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Just use a match or butane lighter. Hold it a couple of inches below the heat shrink and keep it moving.
Old Nov 06, 2003, 10:44 AM
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Very good video Andy. I have a 40 watt soldering iron from Radio Shack....what tip and iron are you using?

I've been using a soldering gun to do my Sermos connectors...

I may go pick up a few packs of Deans to see how I like them. My only beef with Sermos has to do with the fact that I can't get 12 gauge wire in the contacts. Consquently...you have to snip a little wire so they fit in the contact. This creates a little more resistance....

On the other hand....the Sermos connectors daisy chain without harness adapters.....with the Deans...you would have to make adapters to series two packs right? This would also create more resistance....

There's no free lunch here...
Old Nov 06, 2003, 10:51 AM
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I'm not trying to change the world. I just have no problem soldering (or unplugging) these connectors. I've measured the resistance of all types except the 4mm gold pins, and was happy I had chosen the Ultras.

I use a 40W Weller iron. My old RadioShack one died, so I picked up a new Weller @ Home Depot for $15. Has a larger chisel tip than the previous RadioShack one..
..a


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