Large 1/4 supports

[Gregor77]

I am at the point I need to solder some supports for the DR-1.  Can someone give me some tips on how and what to buy?   The instructions said not to use a torch but a 100W iron.

[piker]

What kind of supports?  Do you mean the Cabane Struts and Interplane Struts?

[Gregor77]

Both....

[Michael]

Wrap joints firmly and neatly with copper wire, and then heat up (very hot) with a solder gun or iron, and let the solder melt in smoothly, to a nice shiny smooth coating.

[piker]

Yes, and I'm going to add a "secret" that took me many years to learn... actually, Jack Humphreys told me... but I tell ya, the light bulb went on when he did 'cause for YEARs I could never get a satisfying solder joint on large music wire.

The secret is "acid flux"!  A life safer for sure (well, a solder joint life safer).

I use the clear liquid stuff that I've had a bottle of for years.  Just brush a little onto the wrap before you solder and solder away.  I use an 80 watt iron that I've had since my battery pack building days.  Works like a charm.  Make sure you give some time for the heat to work it's way into the joint and add only enough solder to cover the wrap and anywhere else you want to join.  Too much and the excess will pool /drip below.  If that happenes, you can just file off the excess later.  Keep the joint VERY still while it cools and solidifies.  It'll take longer than a typical electrical wire joint because of the greater thermal mass.  Clean the jont after with soap and water, or Acetone (but wear gloves when using Acetone.

And avoid the fumes from the solder and especialy the acide flux!

One more point.  Using acid flux and, I think, Acetone removes some protective coating from the music wire.  You need to either clear coat or paint afterward, or both, to prevent rusting... especially when building float struts.