Soldering headset wires (Tips needed)

flexy

Diamond Member
Sep 28, 2001
8,464
155
106
I am not a newb when it comes to DIY and I do electronics stuff incl. soldering since...well since I can think. I don't remember ever having this problem.

The problem is in particular fixing *'**/!%%!" headset wires. Since we have cats, I fix on avg. 400 headsets per week since they chew through cords. Ok, sorta, but you get the idea.

I have a no-frills soldering station, but for the other stuff, in this case the solder, I rely on a Chinese dollar store around the corner. (And this is not meant derogatory or whatever, but the Chinese dollarstore carries stuff of the lowest quality, is just a fact)

So, those darn headset wires have laquer (SP?) on them which I need to burn off, I also tried with nail polish remover but this doesn't work. After I burn the insulation off, I wipe the ends of the wires it with alcohol to get the black gunk from the burning off.

The problem is, I can solder until blue in the face, the wire simply doesn't "take" the solder, whatsoever. I have no problems soldering other stuff like boards when I replace caps, whatever, but soldering these wires together is virtually impossible.

Is it the solder I am using, do I need a better one which has flux in it? (The one I have has something in it but I don't know what it is)), all I know is that I cannot solder two simple wires.

So, the store also has something for soldering, it is a solid, HARD chunk of "rosin" (colophony) i guess.. I tried to use it, but don't even know how since it's hard as a rock. I tried to dissolve some of it with alcohol to make a paste, but this doesn't work either.

I remember from years ago when I did soldering work, I had quality solder and the flux was the consistency of vaseline. You simply dipped a wire end into it and everything worked beautifully. Should I simply get quality solder/flux and all my problems are solved? What is it I do wrong trying to connect simple headset wires?

It's something which ****es me off to no end because I must have spent 1-2 hours today for something which shouldn't take longer than 5 minutes. (Also, when I "drill" the ends together without soldering, the connection is more than finicky, suggesting that there is still insulation on the wires despite me having it burnt off)
 
Last edited:

nakedfrog

No Lifer
Apr 3, 2001
59,229
13,815
136
Might I advise the purchase of a headset that allows use of simple 3.5mm to 3.5mm cables?

Offhand, yeah, I'd say to give flux a go. I do so little soldering that I just have this spool of rosin-core solder that I couldn't even tell you where I got, and can usually get things done.
 

Elixer

Lifer
May 7, 2002
10,371
762
126
Usually, you need to burn off* (or use acetone, or scrape off with a blade) the enamel/laquer coating they got on there, then tin the wires first, then go ahead and solder them to the new connection.
*If you burn it too long though, it will oxidize, and, well, good luck trying to get solder to stick.
 

ViRGE

Elite Member, Moderator Emeritus
Oct 9, 1999
31,516
167
106
I've never quite had the cat problem, but I've been in the same boat before with repairing headset cables. I have to admit, I only ever successfully fixed one Sennheiser cable, and that was it. The cable is just too thin and hard to work with; it's not something that's meant to be repaired.

Unfortunately I suspect Who may be right, and the more practical solution is dealing with the cats, despite the fact that it's an actual application of herding cats. Otherwise I don't see anything you're doing wrong here; it's not a problem of skill.
 

twinrider1

Diamond Member
Sep 28, 2003
4,096
64
91
Sounds like you might need this often enough to be worthwhile. I'd probably soak the stuff in lacquer thinner and use a scotch-brite pad.
 
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