Maker Pro
Maker Pro

Stiff wire (not copper?), how to repair/reconnect?

R

redbelly

Jan 1, 1970
0
I am trying to reattach 2 broken wires on one side of a pair of
headphones, but normal solder is not working.

When I scraped off the insulation from the wires, I noticed that the
metal is really really stiff and brittle (though I was able to bend it
without breaking), very unlike copper. Tried soldering it to reattach
it anyway, but the solder didn't stick. (FWIW, I used rosin-core
60/40 solder)

So, my two questions are, (1) what the heck is this wire made of,
anyway? and more importantly (2) is there any way a home hobbyist can
reattach such wire?

These are just a regular pair of light-duty headphones, with a
standard 1/4" phono plug for a stereo system. The wire is stranded,
28 AWG or smaller (i.e., my 26 AWG stripper is too big for it). Is
there some standard material, other than copper, that is used
typically?

Thanks for any help, suggestions, etc.

Mark
 
H

Homer J Simpson

Jan 1, 1970
0
So, my two questions are, (1) what the heck is this wire made of,
anyway? and more importantly (2) is there any way a home hobbyist can
reattach such wire?

If there was thread material in it then it may be tinsel. If so it may be
aluminium.
 
P

Puckdropper

Jan 1, 1970
0
If there was thread material in it then it may be tinsel. If so it may
be aluminium.

That's my thought, based on how the solder's acting. What color is it?
A grey-ish metalic? (Dare I say an "Aluminium" color?)

Puckdropper
 
R

redbelly

Jan 1, 1970
0
That's my thought, based on how the solder's acting. What color is it?
A grey-ish metalic? (Dare I say an "Aluminium" color?)

Puckdropper

Yes, it was gray or silvery. Until I tried soldering and it turned
rather blackish, perhaps from some burnt flux or insulation on it.

Thanks,

Mark
 
H

Homer J Simpson

Jan 1, 1970
0
Yes, it was gray or silvery. Until I tried soldering and it turned
rather blackish, perhaps from some burnt flux or insulation on it.

It's wrapped around a core of cloth/thread. That may have burned.
 
R

redbelly

Jan 1, 1970
0
It's wrapped around a core of cloth/thread. That may have burned.

Okay, that may be what happened.

Went to a local supply store today, that professional electricians
use. They did not have crimps for wire this small, but an electrician
who happened to be in the store overheard me and gave me a few from
his own supplies. Will see how they work out, but it'll need to wait
until the weekend.

My wife will be pretty happy if I get this thing repaired :)

Thanks again,

Mark
 
J

JeffM

Jan 1, 1970
0
redbelly said:
[...]local supply store[...]did not have crimps for wire this small,
Mark
*Size* is NOT the biggest factor.
but an electrician who happened to be in the store overheard me
and gave me a few from his own supplies.
You may get that to work, but I wouldn't bet on it.
The special lugs for tinsel wire have little spikes
that stab THROUGH the cloth insulation.
(There is no stripping.)

I should have mentioned this before. Sorry.
 
Top