- solder the wires end together
Bare back ~1/4 inch of bare wire at each wire end to be joined and solder tin them.Take some ~ 3 inches of AC line cord and strip off its insulation to be able to get two strands of its many- many tiny bare copper wires . . . if they are being tinned . . . . so much the better . . . as you would need to tin the bare copper wires anyway.
Place the bared wires to be joined, side to side to each other. Take the length of prepared fine wire and about its mid point , place it against the center of the
LARGE wires to be spliced
Keep the wrapping wire taunt and start winding it outward from the splices center and end up with a conforming wrap to the end of the wire.
Rotate the splice and do the same with the free half of small wire, also having a tight wrap, now solder your wrapped joint.
- use silicone to create a first layer of insulation over the solder joint approximately as thick as the existing insulation of the cable
I can't see that you will readily be able to easily find the CORRECT formulation of silicone rubber . . . . eg . . . one that is
NOT using acetic acid as its curing agent.
Because any trace of acetic acid that is present and has not weeped or will be weeping out will be a SUPER conductor at 25kv.
Instead, my procedure would be to use the same progressive 2 or 3 larger widths and layers of heat shrink as below, and you
FIRST put them on and slip towards a free end
BEFORE you splice the wires.
Now, instead of the l o o o o o o n g wait required for silicone shedding all traces of acetic acid, instead, take a plastic drinking straw and hold against the splice to be able to cut it to a length of ~ 1/8 inch greater on each end of the splice.
Then you use a hot glue gun to RAPIDLY build up a coating around your bare splice and rotate the cut straw to center on your splice. It should have rotated the still workable hot glue around the splice and cut its way thru and trim down the diameter of fill materiel..
- when the silicone has cured, add 2 lays of heat shrink tube that overlap each cable by at least 1 cm (more is better)
When the hot glue has cooled down, do the centering of and shrinking of the layers of heat shrink tubing.
Keep this whole length og HV wire about 2 + inches dressed away from anything that it might be routed by.
Tha a a a a s s s s s it. . . .
73's de Edd . . . . .