How to Solder Flexwatt(Pictures)

I am making this due to the tons of threads asking about how does flexwatt work and soo on. So maybe this will Help out on how to get it situated.

Materials needed:
Flexwatt
Wire Cuters
Extension cord
Solder
Solder Iron
Razor
Electrical tape

http://i4.photobucket.com/albums/y14...g/100_2741.jpg
First thing to do is Cut off the Female end of the extension cord and Prime the ends with solder which makes it easier to solder.
http://i4.photobucket.com/albums/y14...g/100_2743.jpg
Second you need to take the piece of flexwatt and melt away the plastic over the metal peices on the ends. This allows for metal to metal connection. Use the solder iron to melt it away but DO NOT go over onto the black. Once its melted youll need the razor to scrape it clean of the melted plastic.
http://i4.photobucket.com/albums/y14...g/100_2744.jpg

Third is time to prime the flexwatt in the spot you just cleaned. Take the solder and make a small pool of solder on those metal pieces you cleaned. Doing this makes connection a snap.
http://i4.photobucket.com/albums/y14...g/100_2746.jpg

Next take one end of the extension cord and attach it to the flexwatt by slowly fusing the 2 pieces together.
http://i4.photobucket.com/albums/y14...g/100_2747.jpg

Next Cover the Connections with electrical tape for your safety. Be sure to cover it completely and also a small piece o nthe opposite ends just in case. Once you have them taped off Plug it in and check it heats up by either feel or temp gun. If all is good CONGRATS as you are finished.
http://i4.photobucket.com/albums/y14...g/100_2748.jpg
http://i4.photobucket.com/albums/y14...g/100_2750.jpg

You should mention to use electrical solder and flux or flux core, or the solder wont stick.
Be sure not to get a cold joint. Don't move it while the joint is molten. A bad solder joint can cause uneven heating as well as being a fire hazard.

Might be a good idea to practice on a small piece if you are not experienced at soldering.

The solder i use is Rosin Core .032 diameter

I just do it the easy way and pay the $0.50 for the clips....

solder gives a better connection. The clips are going through plastic and not 100%. I have the crimper for them clips and i get better/faster heating with the solder.

If you scrape off the plasic coating on the flex wont that give you a nice steady connection with the clips to the tape?

yeah i solder also and i have noticed that the soldered heat tape does better, and it easier to use the tape afterwards because you dont have them big clips to deal with.

Very informative post for the noobies to FlexWatt!
:cool:

just curious, would a box cutter be an efficient tool to use to cut flexwatt down to a smaller length? if not what is?

Quote:

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Originally Posted by BGdyl

just curious, would a box cutter be an efficient tool to use to cut flexwatt down to a smaller length? if not what is?

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Scissors