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This �pen type� soldering iron was modeled after a Weller 25 watt unit. To start, I machined the brass �core� from a solid length of 1� brass rod. This was turned to the dimensions in diagram 1. It was also drilled and tapped for 3/8 � 16 threads. This is the standard size I am using on all my interchangeable tips going with the modular design of the system. This will allow me to use the carbon rod tip from my soldering �gun� or fashion custom tips to suit a particular soldering job. The tip I made for this iron is drilled to accept 3/16� stainless steel electrodes. I use brass punches with a hex body to make the tips. The hex shape provides a way of tightening the tips into the body. The punches are cheap and turn quite well. After the core was completed, I drilled out a solid block of black walnut wood that would �screw� onto the brass core to form the handle. Using the core as a mandrel, it was turned on the lathe. I used the proportions from the Weller to determine the handle dimensions since I liked the way the Weller feels. The handle was sanded smooth with 320 grit sand paper and sprayed with a clear lacquer to preserve the wood and add to the durability of the unit. The last detail was to drill the back end of the iron to accept a standard banana plug. This iron is quite simple in the design but had proved very useful for delicate jobs. |
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