Anyone solder wires into mains plugs?

[Steve Browning]

Seems an obvious thing to do in some respects. Does anyone do it?

 

Why shouldn't you, if there's a reason why not.

[BigRedX]

You shouldn't because the screws on the terminals don't clamp down as efficiently onto soldered wire as they do onto stranded.

 

If you are talking about actually soldering the wires in the mains cable to the contacts in the plug, then the heat required to do this would most likely also melt the conductor insulation on the mains cable.

[neepheid]

No, I've never done it and I've never even thought about doing it until you mentioned it the now.

 

Nope, still not doing it. I don't see what value it brings - the UK plug is already over engineered to the nth degree (which is why it's the best plug design on the planet - fight me).

 

Reason why not? Apart from it being completely unnecessary, it would make replacing a worn cable a bigger job than it needs to be.

[itu]

I've seen welded, but never soldered cables. Tinning copper makes it brittle, which can lead to scary end results. 

[Steve Browning]

13 hours ago, neepheid said:

 

Reason why not? Apart from it being completely unnecessary, it would make replacing a worn cable a bigger job than it needs to be.

Like putting wheels on a tomato, I guess.

 

Not experienced a worn cable personally. I was mainly thinking of the effect of the cycle that, apparently, gradually loosens the screw. 

 

I wonder how moulded plugs are done?

[BigRedX]

If the screws are working loose then I would suggest the plugs are either poorly made or the screws haven't been sufficiently tightened. I don't think I've ever come across screws working loose. Even if they did, due to the construction of a standard UK mains plug it should make any difference if the cable is properly clamped in place there is nowhere for the conductors to go even if a terminal screw were to work loose.

 

As for moulded plugs has anyone cut one apart to see what's inside? I doubt that they are soldered. AFAIK the moulding process holds everything together so there wouldn't be any need for it and besides the heat of the moulding process would probably affect the integrity of any solder joints.

[neepheid]

1 hour ago, Steve Browning said:

Like putting wheels on a tomato, I guess.

 

Not experienced a worn cable personally. I was mainly thinking of the effect of the cycle that, apparently, gradually loosens the screw. 

 

I wonder how moulded plugs are done?

 

Well, I have (admittedly this example is at the device side, not the plug side)

 

 

But if this had been at the plug end, I would not have been happy to find a soldered plug. Might have chucked it in the bin and got another one if that was the case.

 

To be honest, in this day and age of moulded plugs, it's getting pretty rare to have to wire a plug.  But I stand ready to do so.

 

As for screws coming loose - you can always tighten them up. Not that I've ever experienced a screw come loose at a plug prong through basic usage. The cable grip, aye, occasionally.

 

Never hacked apart a moulded plug, hmm - might do that one day if I'm at a loose end

 

[JPJ]

1 hour ago, neepheid said:

 

Never hacked apart a moulded plug, hmm - might do that one day if I'm at a loose end

 

I did once, and the cables were clamped in place mechanically, two prongs bent over the exposed cable ends which themselves had an aluminium sleeve over the copper wire. Looked like it had been done in a press. 

[nekomatic]

4 hours ago, neepheid said:

Well, I have (admittedly this example is at the device side, not the plug side)

 

To be fair, that particular piece of kit has to be a good 40 years old.

 

Model A or B, btw?

[neepheid]

1 minute ago, nekomatic said:

To be fair, that particular piece of kit has to be a good 40 years old.

 

Model A or B, btw?

 

B - in the process of being restored, PSU caps done, but mucho funny business being displayed ATM.

[itu]

Molded plugs usually have crimped or welded connections. I think crimping is the most popular way because it is fast, cheap, and reliable. 

[basstone]

10 hours ago, neepheid said:

 

Well, I have (admittedly this example is at the device side, not the plug side)

 

 

But if this had been at the plug end, I would not have been happy to find a soldered plug. Might have chucked it in the bin and got another one if that was the case.

 

To be honest, in this day and age of moulded plugs, it's getting pretty rare to have to wire a plug.  But I stand ready to do so.

 

As for screws coming loose - you can always tighten them up. Not that I've ever experienced a screw come loose at a plug prong through basic usage. The cable grip, aye, occasionally.

 

Never hacked apart a moulded plug, hmm - might do that one day if I'm at a loose end

 

Fairly common stress point where a cable goes through a gland, also happens on mains cable reels where the cable goes into the centre hub. This shows perfectly why we should regularly inspect our gear for safety or better still get it PAT tested which can also reveal hidden issues before they get seriously dangerous! As to soldering rewireable mains plugs - they're not designed for that and best to either use crimped finger terminals or just twist and double back the stripped conductors. In my experience moulded plugs are much more reliable although do watch out for dodgy oriental imports with insulated earth pins.