Electrical wires are generally used to connect parts of an electrical circuit that are not positioned on the same surface. The electrical wires then extend from one surface to another, and are therefore exposed to abrasion and wear. If an electric wire is damaged, it does not have to be replaced. In fact, you can restore the circuit simply by rejoining two ends of the electric wire. Read this article to find out how.
Steps
Step 1. Locate the damaged area
The metal conductor of the electric wire is covered with plastic insulation which should appear smooth. You may notice signs of breakage, blemishes or burns on the insulation, at the damaged area of the electrical wire.
Step 2. Delete the damaged area
Use electrical wire pliers to trim the ends.
Evaluate the size of the cut. The cut part should be long enough to completely eliminate the damaged area, but without eliminating the intact parts. In fact, if the two ends are too far apart, the remaining wire may not be enough to rejoin them
Step 3. Throw away the cut section of the electrical wire
Step 4. Remove the insulation from the two new ends of the electrical wire
Remove about 2 inches of insulation from each end.
- Choose the appropriate opening of the caliper. Normally these electrical cable pliers have different opening levels, each of which should report the corresponding wire size.
- Select a generic opening level if you don't know the size of the electric wire. If you are unsure of the size of the wire, choose an opening that will allow you to remove all the insulation. Make sure it is wide enough not to damage the copper wire inside the jacket.
- Squeeze the pliers. Place the pliers about two centimeters from the end of the thread. Hold the clamp firmly as you squeeze and pull the insulation off.
Step 5. Create the links
If the thread is made up of many thinner filaments, twist them together gently to form a cylindrical body. If the wire is made of a single piece, it will not be necessary.
Step 6. Place the heat shrinks
To insulate the new ends, cut a piece of shrink wrap about twice the length of the cut area. Run it to the end of the electric wire; push it away from the joining area so that it does not heat up prematurely during the rejoining operation.
Step 7. Connect the ends of the wire by twisting them
Carefully twist the ends of the wire, following the direction of the wire; do not bend it at the point of rejoining. The resulting seam should look just like a continuation of the original thread.
Step 8. Prepare the weld
Put a small amount of tin (or other solder) on the tip of the soldering iron. It will become liquid.
Step 9. Solder the wires
Gently place the tip of the soldering iron on the central part of the junction of the wires. The wire will heat up to the point that the tin will melt.
- Go slowly. Apply enough solder to cover the joining area of the wires, but do not overdo it (avoid forming lumps of solder, which will prevent you from seeing the wire).
- Get the weld fixed. Remove the soldering iron from the wires. Hold the wires until the solder solidifies; when this happens (generally it takes about ten seconds) the weld should appear more opaque.
Step 10. Isolate the junction
- Fix the heat shrink. If you used heat shrink, slide it to cover the joint. Use a hot air gun, and heat it until it fits the surface of the joint. Do not heat too much or it could break and burn.
- Wrap the joint with electrical tape. If you haven't used heat shrink, wrap the joint completely with electrical tape.
Advice
The heat shrink becomes very brittle if it is not heated evenly. Do not try to heat it using the soldering iron or the lighter
Warnings
- Don't wrap the threads together by twisting them, like you would tie a knot on a bread pack. You will get too thick a joint which will give you problems during the welding process. It will also create a discontinuous surface which could damage the new insulation.
- The soldering iron tip and tube become very hot; if you touch them you will burn yourself instantly. Keep the soldering iron straight and tight as it heats up before use, and as it cools down after use.
