Urgent: Help needed with soldering a 3.5mm plug connector.

Jan 28, 2012 at 5:50 AM Thread Starter Post #1 of 7

Omark12

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Okay So I'm currently in the process of recabling my Denon D2000s but i'm having serious trouble with attaching the connector to the cable, I already made the cable and soldered it to the drivers and it actually looks pretty nice, but its not terminated. I was originally using a Rean 3.5mm mini plug, but that one was destroyed in the process of soldering on the wires, the plastic insulator right before the plug melted. So I went bought some new plugs from radio shack. A 3.5mm and a 6.3mm plug. The 6.3 melted like the Rean. And the smaller, the 3.5mm which is identical to the Rean one, I have yet to test out, I already soldered it on but I have a feeling it wont work. The solder joints I made are really sloppy and I just cant figure out how to properly solder the connector. I looked at a few youtube videos but its way harder than it looks to me. Is there any step by step detailed videos on how to do this? Is there a particular soldering iron tip i need to use? Anyway its hard, how do I do it. Also is there any place I can the the cable and a new plug and have them solder it on for me? (location: Rancho Cucamonga, CA)
 
Also the stuff im having trouble with:
  1. How much copper should I expose when I strip the cable
  2. How to get the wires to actually fit in the tiny space of the connector
  3. How do I make a clean joint and how to i keep the wire down on the flange, I only have 2 hands
 
Just ask if you need anymore info on the cable
 
 
Jan 28, 2012 at 10:30 AM Post #2 of 7
By plastic insulator I assume you mean the piece that holds the pins (for the wires) in place and not the clear sheath that slips off. After many failures myself I would suggest a pencil style soldering iron (not gun) no more than 30W, a fresh tip with a very small point, electronic or high-tech solder, a "helping hands" tool to hold the wires while you solder, keep your tip freshly tinned (silver not brown or black) while you solder and be patient. You can do it, just might take some tries to practice getting the wires in the right place using one of the bad plugs first.
 
Jan 28, 2012 at 10:35 AM Post #3 of 7
Also, only strip enough wire to be soldered to the pin so one wire doesn't touch another pin. The Radio Shack plugs I got have screws so I tinned the wires then screwed them on before soldering. Also, I used electrical tape to shield afterward instead of the removable clear plastic sheath.
 
Jan 28, 2012 at 10:42 AM Post #4 of 7
pre tin both the wires, and the connector, so you don't need to keep the heat on it as long. A little flux might help as well. And as per determinedd above, keep your tip tinned too. 
 
Use a helping hands alligator clamp to act as a heat sink on the connector (make sure it is clamped on the on the part your are soldering: tip/ring/sleeve), that will help prevent melty.
 
Jan 28, 2012 at 10:55 AM Post #5 of 7
Just give advice, give a little solder flux first @the connector joint tap then you will melt them with 60-40 rosin core solder, strip the wire (around 1-2mm) and give the copper wire with the flux( just a little dip), and also don't forget to put the connector cover first before you do any connection between the cable with the connector, and gud luck
normal_smile .gif

 
Jan 28, 2012 at 12:17 PM Post #6 of 7
 
Good advise.
 
Flux is your friend. Don't ever rely only on the flux in the solder. That's only there to keep flux flowing as you continue to add solder when you need to.
 
se
 
 
 
Jan 28, 2012 at 1:10 PM Post #7 of 7
Thanks for all the replys guys! I really appreciate your help. I got my D2ks recabled successfully.
 
Quote:
Also, only strip enough wire to be soldered to the pin so one wire doesn't touch another pin. The Radio Shack plugs I got have screws so I tinned the wires then screwed them on before soldering. Also, I used electrical tape to shield afterward instead of the removable clear plastic sheath.

I didn't end up putting electrical tape or anything on the flanges, I was scared that if I had worked around them i would accidentally destroy the joints I had made.
 
 

 
Quote:
By plastic insulator I assume you mean the piece that holds the pins (for the wires) in place and not the clear sheath that slips off. After many failures myself I would suggest a pencil style soldering iron (not gun) no more than 30W, a fresh tip with a very small point, electronic or high-tech solder, a "helping hands" tool to hold the wires while you solder, keep your tip freshly tinned (silver not brown or black) while you solder and be patient. You can do it, just might take some tries to practice getting the wires in the right place using one of the bad plugs first.

Yes, thats what I was talking about, I don't have a "helping hands", so I used my real hands and burned them quite a bit in the process. Also my Iron was 45w with no heat control, yes, it was very difficult.
 
 


Quote:
pre tin both the wires, and the connector, so you don't need to keep the heat on it as long. A little flux might help as well. And as per determinedd above, keep your tip tinned too. 
 
Use a helping hands alligator clamp to act as a heat sink on the connector (make sure it is clamped on the on the part your are soldering: tip/ring/sleeve), that will help prevent melty.

What I ended up doing was threading the wires through the little holes in the flanges then I melted some solder on the tip of the iron and dabbed it on the flanges creating a "joint", it was a really dodgy soldering job but i guess it ended up working out in the end. I was the heatsink this time around.... Oh and I used the 3.5mm plug from radio shack, works really well.
 
 


Quote:
Just give advice, give a little solder flux first @the connector joint tap then you will melt them with 60-40 rosin core solder, strip the wire (around 1-2mm) and give the copper wire with the flux( just a little dip), and also don't forget to put the connector cover first before you do any connection between the cable with the connector, and gud luck
normal_smile .gif


I used 60-40 solder which i reckon is better than the cheap crap that came with my iron. I don't have flux, but I got the job done somehow.
 


Quote:
 
Good advise.
 
Flux is your friend. Don't ever rely only on the flux in the solder. That's only there to keep flux flowing as you continue to add solder when you need to.
 
se
 
 

Thanks, I'll remember to buy flux next time around.
 
Now, how do they sound? Well the improvement is very generous for the money I payed to recable them. Everything is more refined, its a bit brighter, the bass is now very clear, less muddy, and the soundstage has improved slightly. I didnt think recabling could actually change sound. But Im more surprised they work after my crappy soldering job, also I wasnt able to read your guys' replies before I finished the job, but thanks!
 
 
 

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