posted 02-02-2008 07:58 PM ET (US)
Tom,
If you can, comb out the strands and try an eraser first or clean them with alcohol or somthing like DeoxIT (R-Shack?). I have used a small wire brush with good results. A small piece of cardboard behind the wire strands will help support them. Pull from the center toward the ends. A little clean beats a lot of flux. I would stick with the Rosin Flux. If you think things are corroded now, using Acid Flux will really show you corrosion 6 months from now.
Safety first. Good ventilation and all that. Enough Lead injestion and you will forget we had this conversation. Be careful of the alcohol fire hazard. Eye protection is a must, we will be flinging molten metal.
Your iron should be big enough to complete the joint in 2-3 seconds. Any longer and you risk wicking the solder under the insulation, losing the flexability of the wire.
Use a sponge or a damp paper towel to "shock " the contaminates off the iron just prior to soldering.
Always cut you solder, don't strech and break. It messes up the Rosin/Solder mix.
If needed set up a wind break to keep the heat on you project.
Don't blow on the joint to cool it. This will make a "Cold Joint".
You can use the solder as a washing agent but you have to be mindful of the heat on the wire and insulation. You can do this by "tinning" the wire a few times and allowing the excess to be pulled off aroud the iron. Start by placing the iron at the insulation end of the wire, feed solder into the junction untill you have a nice "bubble" of solder, then skid it down and off the end to a waiting damp paper towel.
Smaller heat shrink around the conductors would be better that tape. Making that work will require the fast on/off technique I described to avoid the tubing shrinking in the wrong spot.
Double check that you tubing is on the wire before you complete the joint. I have never forgotten it, and won't ever do it again.
Good Luck,
John