Wire Soldering Techniques

Mastering the technique of wire soldering is a useful craft that can help you splice electronic wire, fuse jewelry metals, hang your favorite artwork with copper wire hangers or even create wire sculptures. Indeed, wire is a flexible tool with numerous applications. Soldering does require some practice and patience, however, so if you're new to the craft, spend some time with practice wire before you tackle the main project.
Preparation
Before you begin, make sure the wire is thoroughly clean. Any dirt, oil or grime will inhibit the solder from adhering properly. Scrape the wire with steel wool, sand it down or dip it in soldering flux to make sure it's clean. Do not handle it with your fingers as natural oils will stick to the wire. Use tweezers or tongs, and place it in a vise to hold it as you work.
Gather your tools: a hot soldering iron, chemical flux, a flux applicator brush (or natural-hair paintbrush) and flux remover. Make sure the room is well-ventilated, as flux is a corrosive, deoxidizing chemical that can emit harmful fumes. Finally, protect yourself with work gloves and a clean, cotton respiratory mask.
Fluxing
Apply a thin coat of flux to the wire, using a flux-applicator brush or natural-hair paintbrush. For electronic wire, use flux that does not leave a residue and is designed specifically for electronics. This will be indicated on the bottle. Coat the wire evenly, and be sure to apply just the right amount. Too much flux can cause the solder to bubble, and too little will prevent the solder from properly adhering.
Soldering
Make sure the soldering iron is fully heated before you begin to flux. A warm iron will not solder properly, and you should be ready to solder before the flux has dried.
Apply a thin layer of solder to "tin" the wire. Tinning is the process of applying just enough solder to coat the area to be soldered. Then, twist the tinned wire pieces together to create a joint. Dab the soldering iron with a damp sponge to clean it. Be sure to wipe the iron after each application so the solder flows smoothly. Solder the twisted wire with a further thin layer to secure the joint. Clean the wire of any remaining flux residue with flux remover. For electronic wire, protect the soldered joint with PVC shrink tubing.
Recommended wattage for a wire soldering iron is 60/40 solid lead core. Lead-free solder is also available.

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