How to make a soldering iron on batteries

Battery-powered soldering iron is an indispensable tool for electrician, radio electronics or electrician. However, what to do if the tool is missing, and urgently need to solder? The answer is simple. You need to make a soldering iron on the batteries with their own hands. In this case, it will not look like professional and commercial models, but it will work just as well as that acquired in an electrical appliance store.

Soldering iron model with batteries

The soldering iron, made by hand, is as good as the store counterparts.

What tools and materials will be needed to make such a soldering iron?

In order to make a soldering iron with your own hands in conditions of a house or a workshop (approximately 25-40 W, to solder chips, wires and other products), you must have:

Parts for assembling a soldering iron do it yourself

Details for assembling a soldering iron: a ballpoint pen body, an MLT resistor, copper, steel wire, two-sided PCB.

  • a newspaper;
  • pliers;
  • office knife with replaceable edges;
  • stationery scissors;
  • insulating tape;
  • copper wire for the tip of the soldering iron;
  • a small sheet of copper foil;
  • an iron tube (to be used as an electric heater case);
  • heat-resistant plastic or wooden handle;
  • any silicate adhesive or water glass;
  • talc powder for electrically insulating mass;
  • 2 AA batteries.

Making an electric soldering iron with your own hands is a fairly simple procedure that many masters will not cause any difficulties and difficulties.

The listed materials and tools are easy to find in any workshop, and in the absence of it - to purchase in the nearest electrical goods store.

If it was not possible to find a sheet of copper foil in the workshop, it can be replaced by foiled glass fiber - material that is often found in printed circuits and boards (the price of this component in electrical stores is about 200 rubles / sheet).

To separate the foil layer from the PCB, you must:

  • heat the PCB sheet with an electric soldering iron or iron;
  • wind the edge of the foil on the body of a round pencil;
  • as you move along the surface, wind the foil on the round body of the pencil in the form of a dense tube.

When performing this operation, it is important to observe the utmost accuracy and evenly coil the foil, preventing its damage.

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Making a future soldering iron tip

Soldering iron heating element

To remove paint from a resistor, heat it with a power supply.

To make a soldering iron tip with your own hands, you need to take a thick piece of copper wire and sharpen one end of it at the required working angle (this work is best done on a table covered with newspaper, and use a regular office knife with replaceable blades and a small file as a working tool).

The angle of sharpening of a standard tip can resemble a spatula or a screwdriver point, which has a dihedral angle of the working surface with a bevel radius of 45 degrees. The standard sting can be made with a working surface thickness of 4-5 mm.

The miniature sting can be made 2-3 mm thick. A needle sting, sharpened under a cone in the form of a needle, can be of any thickness of the sting. The sting made under a certain type of work can have a figured shape and any thickness of the tip.

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How should the soldering tip work surface be treated?

The working surface of the tip of the soldering iron must be covered with a layer of solder, otherwise the uncovered part of the surface of the tip will burn. The burning of the non-working part of the sting is uncritical, but the working part must always be in a clean and perfect condition.

If the surface of the tip in the process begins to burn out, it should be re-covered with a layer of solder. The finished tinned sting is used by the master as a heating element of the soldering iron.

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The manufacture of electrically insulating mass

Current lead

The diameter of the resistor and the ring at the end of the wire should be the same.

To make an electrically insulating mass, you should mix the silicate glue (liquid glass) and talcum powder to the consistency of liquid sour cream. Apply the mixture using a rigid inert plate or tweezers on the cylindrical surface of the future soldering iron tip.

The mixture obtained by mixing talc and glue has a very sticky consistency. Therefore, to prevent sticking of the tool, it is necessary to sprinkle it on top with plenty of dry talc powder.

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Making the basis of the heating element of the soldering iron

To make the body of the heating element of the soldering iron, you should wear a tube L = 30 mm made of the finest copper foil on the surface of the tip. This design will be used as the basis of the heating element of the soldering iron. The tip of the sting that comes out of the tube should not be longer than 10 mm.

Soldering iron assembly

For better contact, solder the ring to the resistor head.

The finished design of the heating element of the soldering iron should then be covered with a thin layer of electrically insulating mass and dried over a hotplate of a gas or electric stove at a working surface temperature of at least 150 degrees. The drying process should be continued until the layer of mass becomes solid (caked).

Then follows the spiral winding on the prepared heating element. To perform the procedure, use thin (d = 0.2 mm) nichrome wire approximately 350 mm long. Winding should be done in a spiral with great care, tightly winding wire coil on a coil.

The ends of the wire should be placed outside the heating element straight. And one of the ends of the wire should have L = 30 mm, and the other, turning, L = 60 mm.

The made winding should be covered with electrically insulating mass and repeat the drying process according to the previously described technology.

After the insulating layer has dried, the long end of the wire should be wrapped around the body of the heating element and attached tightly to the body of the tube. The next step in the manufacture of a soldering iron should be the final application of an electrically insulating layer and the repetition of the process of drying it.

At this stage, the manufacturing process of the heating element of the soldering iron can be considered complete. Before proceeding to the final stage of making a soldering iron, the master should cover the ends of the wires 50% of the length of the heating element with an electrically insulating solution.

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Build a homemade soldering iron

To assemble a soldering iron, the master needs to perform some work:

Install sting

Before installing the tip, place a small piece of mica in the resistor hole.

  1. Connect the ends of the heating element to the body of the batteries (the procedure can be carried out with the help of two twisted copper wires).
  2. Insulate contacts with insulating tape.
  3. Batteries connected to each other should be placed in a heat-resistant plastic or wooden tube - a handle.

How to make a stand for a soldering iron with your own hands? To make the most convenient, compact and functional stand for a soldering iron, you will not need scarce materials. You can make a stand with your own hands from improvised means, for example, from an old rectangular iron box, a lid and remnants of plywood that can always be found in any workshop.

To make a stand, you will need:

  • iron lid or box;
  • rectangular pieces of plywood;
  • wooden beadings;
  • self-tapping screws;
  • nails;
  • tin W-shaped bracket.

Work on the manufacture of the stand should be carried out on a clean table, covered with a newspaper. Initially, three strips are cut out of plywood, one wide and two narrow. The wide rectangular bar will be used as the base of the stand, the other two, the same, will be used to fix the box for the soldering iron. If round holes are made in one of the slats, then it will be possible to place jars with flux for soldering in them.

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Stand making

To make a stand, you need to perform a number of manipulations:

  1. From plywood cut one wide and two narrow strips of the same length.
  2. On the surface of one narrow plank cut round holes (they will allow to install jars with fine details: flux, solder and rosin).
  3. The iron box with screws on the sides tightly fasten on narrow plywood blanks.
  4. The bulk construction should be tightly fixed on the flat wide surface of the plywood.
  5. Attach the tin W-shaped bracket tightly against the round holes (a soldering iron tip will rest on the structure).
  6. Under the plywood under the tin bracket to install the edges of the wooden beadings.
  7. Place a cellulose sponge in the iron lid to clean the soldering iron tip.
  8. Install containers with flux, solder and rosin into round holes.

At this stage, the manufacture can be considered complete. Now the soldering iron can be installed on the surface of the stand and they can solder any necessary parts.

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