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RMU's and Display Units by Project45

hmmm that is a good idea Ron!

I did receive some nice knobs from china, they do look nice, and fit well to the DU.

So still figuring out which to use.

Hey guys, first, I want to apologize for not posting more news and updates.  I can assure you that there is a ton of work being done in the background to get our Lear45 V2.0 up and running!  During this process sometimes things come up that I realize might need a quick tutorial on.

In this case, how to solder 22 gauge wires to a clad board, especially those wires that have to get "U" turned around.  In the future, clad boards like this will eventually be replaced with PCB to eliminate this small problem.  In the meantime, here are a couple tricks that I use to get the job done.  By the way, I know there are many ways to skin a cat, this is just one way to go about it that I found to work very well.

Two things that you will need besides the obvious and that is Scotch tape and the fat edge of a work table.

(Right click on all photos to get a real close look)


What the tape and edge of the table does is acts like a couple extra hands.  And if you have done much soldering, you can never have too many hands!  In the photo above, I have the LED ground line already soldered and I am ready for the power line.

In this photo below, the red wire is already soldered to the clad but what happens even though I try to avoid it, the wire ends up with some exposed wire and needs to be pushed back up into the clad.  Here I have the clad sitting on end holding it with my pointer finger and with my thumb and middle finger, I am getting ready to push the wire into the clad.  My left hand has the soldering iron and will touch the solder that is already connecting the wire to the clad for just a second, just long enough to gently and carefully push the wire in.  Be careful not to push too hard or you will bunch a ball of wire insulation up on the back side of the clad.


In this photo, all but just one of the wires is soldered to the clad.  To this point, the others have been pushed up to the clad from behind and they all still need to be trimmed.


At this point, the hard and HOT part is over!  Carefully push the wires through the access wire hole making them "U" turn back the other direction.


Last but not least, trim the access bare wire on the back side.  And your done!  This method is actually not too difficult but it can be time consuming.  But once it is done, it's done!


Thanks Ron.  Good information here. I did not use your method and damaged my boards as a result (as you know).  This type of knowledge comes from frequent and direct experience I guess!

Don't attempt to solder the wires AFTER you have bent them through the opening as it stresses the newly soldered joint.

Jason Hite FlightDeckSoft

........ and for those who are too nervous for this close soldering turning into a disaster.

There is also this option. Wire glue. Just put it into google and other sites for purchase will show up.

Coop has recently used it with success so living proof.

Mark S.


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