![]() The crimp contacts are of course higher maintenance and require more cleanliness whereas the solder is just more forgiving but requires more strain relief, the world seems to have done in the direction of crimping because they are better suited in batch production scenarios and so connectors are optimised for crimped terminals and so might not provide as much strain relief where necessary Crimping contacts eliminates the use of solder which will wick up wire strands and provide an excessive rigid patch which degrades the flexibility and strain tolerance of the wire. If you add solder to the voids (we'll assume that the actual metal-metal contact region is so tight that no solder will leach in to it), then as the assembly heats and cools (and thus expands and contracts) the solder will provide a region which expands for tends to separate the nice clean metal-metal region or disturbs the natural movement of the metals. ![]() This is not an instantaneous process and takes a little time for the processes to happen. However, the idea behind crimping is that it should be done so that there is sufficient pressure between all of the metallic surfaces that it slowly 'cold welds'. That should make for a good DIY anchor, meaning you could buy cable in bulk and make your own cables.Hi, For short term or regularly maintained equipment then its really not so much of a bother, additional soldering would guarantee a better INITIAL joint. Then, stuff the cavity with solder (melt it in, jam your iron in, use a torch, whatever). It would include a slot where you lay the cable halfway through it. I imagine it'd be pretty easy to make a little baby crucible out of steel, stone, or something else that melts at a higher temperature than lead. It's like trying to make a sandwich out of phyllo dough, the gaps make for a crumbly product. I tried this at the handlebar end with not such good results, trying to jerry-rig a cable anchor: although the foil layer touching the cable does swage in well, the outer layers are too brittle to hold well together. ![]() The soft lead will press into the cable gaps and should create a very tight nipple. Anyone with a roll of lead-based solder can hammer it out against an iron plate to make a thin foil, then wrap the cable with it, and finally "swage" it by hammering it down.
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