$10ish DIY Variable Temp Soldering Iron Controller

This instructable will show you how to make your Radioshack "firestarter" soldering iron into a variable temperature version using around $10 in parts. This idea came to me after i started lifting traces on a circuit board because I was using a 30w soldering iron to solder on a chip. Plus, I am cheap and variable temp soldering irons cost a lot more than $10. Caution: this instructable deals with household AC current. If you don't feel comfortable wiring things up or plugging things in, this is not for you. Also, this is my first instructable so I'm sorry if it sucks.

Step 1 Parts You Will Need

Tools
Flat Head Screwdriver
Wire Stripper
Tin Snips or a dremel
Hands

Parts
Grounded wire pigtail (mine came from a florescent light, you could just cut the end off an old computer cord. Just make sure it has clearly defined wires. (i.e hot, neutral, ground.)
Romex Connector
4" x 4" Handy Box
Outlet
4" x 4" Handy Box Outlet / Switch Cover + included screws
600w rotary light dimmer + included screws and wire nuts (mine is made by Leviton and was the most inexpensive model at home depot.)
Lamp with incandescent bulb for testing.

Comments

[atlantica]

Can I use this to plug a 1500 watt heater into, thereby controlling the temperature?

[titaniumw41]

No! Don't do it! It the dimmer is rated for 600 watts max, and some of the aluminum for cooling has to be cut off to fit it in the box. It would be a good idea to stay under the 600 watt rating.

[SelanacScreenPrintR]

Do they sell higher wattage rated dimmers we could use instead?

[SelanacScreenPrintR]

After doing a little research I found the Harbor Freight has a Router Speed Control. Basically used the same was as this dimmer. The Router Speed Controller is $19.99 online.

The controller is 120 v x 15 amps. Wattage = Voltages x I (current). So, the Router Speed Controller is rated as 1800 watts.

I found some companies to have 2000 watt dimmers. Did not see one on Home Depots website. Maybe a lighting store would have one. Also, homedepot has a 20 amp Plug/Receptacle. You could probably use that in Titaniumw41's plans with the 2000 watt dimmer to control the heater temperature.

[SIRJAMES09]

Ya did great Chief. :)

you explained it well, the pics reinforced your explanations, if there are any errors in this Ible, the errors(or omissions) were on the side of safety...which is good.

TY for sharing

[sdtacoma]

Great INS. Very easy project to complete.

Quick question... Does it matter which silver screw is used for the white wire? You specify the "hot" side for the black wire, is there a certain side for the white wire? I just picked one and it works but I just want to make sure.

[SIRJAMES09]

not saying it WILL short out, it just makes it easier for the electricity to produce a short.

[SIRJAMES09]

I'm not an electrician, but this much I DO know to be true.

On outlets like the one pictured, you will see 4 screws on the back....

it does NOT matter which screw you use, as long as the screws are both the same....

what I mean is this: if you hold the outlet like shown in the pic you will have 2 top screws(1 on each side) & 2 bottom screws(again, 1 on each side).

It does not matter if you use the top screws or the bottom screws, as long as BOTH are on the top, or BOTH are on the bottom.
If you have 1 on top & 1 on bottom it makes it easier to short out BOTH the outlet AND whatever is plugged into that outlet.

[your_dragon113]

When looking at the outlets... If you remember that "White Is Bright, Black Is Gold and Ground Stands Alone" then you'll never go wrong. MOST times you want to be controling the Phase (Hot(Gold Screw, Black Wire)) as most things are made that way. Neutral is used to return the unused power back to the source (ie: Power plant). You Can control the Neutral but I wouldn't do this for anything that is servicing electronics. This is also why you will always find the Fuse or Breakers on the Phase (Hot).

[SIRJAMES09]

TY Sir....
I never thought of it that way before...TY

[your_dragon113]

;) I hope it helps!

I SHOULD mention that this lil poem only works for outlets in North America...I'm not too sure about other countries that use 110-120 VCA.


....and I want to thank Everyone for all the Great Instructables!

[SIRJAMES09]

if it works in North America, chances are, it will NOT work across the pond....
Europe, Asia, near east, far east & middle east, etc.

what I have been told thru the years is that they have a different set up for electricity over seas than us Americans have.

Now weather that is true or not, I do not know...that is only what I have been told.

[sdtacoma]

Another question...

Does anybody know where in this circuit I could put an LED to show me when the unit is on/off? I would like the LED to be either on or off and not to dim with the dimmer.

Thanks

[SIRJAMES09]

another thing you can do is have a single junction box attached to the double junction box. & then inside that smaller box, have a switch that has a light already in it...it would come on when there is power running thru it & off when there is not.

For those who may not know the terminology, a junction box is that galvanized steel box shaped thing in the pic. what is in the pic is a double junction box....a single junction box is half that wide.

[MROHM]

Yes I Do!!! But It's Far Too dangerous especially at a Beginner's Level!!! Led's draw 10 to 20Ma and shouldn't load down the Dimmer!!! I have used a Led as a Ac Voltage Indicator but feel this project should be geared to our Advanced Electronic Builders!!! Sorry,,That's just how I feel about This.

[mightywombat]

Look for a dimmer switch that lights up when it's on.

[scoobbrandon]

 you would need a relay

[its2l8men]

I used a utility box for this project and put it in the wall, just like a normal outlet but has a dimmer for my soldering jobs.

[CB2001]

Ironically, you not only made a Variable Temp Soldering Iron Controller, you also made a dimmer switch for a DIY lighting kit. :D

[KJ4ZVQ]

OK THIS IS SHEER LUCK!!!!!!!!!! and kinda wierd too. i logged on to finish up my publishing an an i'ble on the SAME wiring circuit, in the SAME desighn, but for a different purpose. lol i built mine for a church event where we needed to dimmcanned lights for special effects. i wondered too, if this would work for an iron, but never tryed. great job and very nice i'ble. you did it more justice than i would have no matter how long i worked on it:)

[HVACRguy]

ALSO you could use an amp meter to see how many amps the iron is using then multiply amps by volts and that will give you watts! you can then mark on your dimmer control box where 15 watts is 20 watts 25 watts 30 watts 35 watts and 40 watts are!!! hope this helps

[alibabbarudolph]

thank you for this instructable... i was actually in the middle of doing this with the same exact dimmer switch, but i didnt know which ground should go where... so thanks a bunch

[MROHM]

If this is your first project you did a fine job!! It's cheap and serves a useful purpose. What else can I say??

[milsorgen]

 Couple thoughts... The Romex Connector I found at Home Depot as 3/8" Clamp Combination Connector sold in packs of 5. They didn't have the exact face plate nor did they have 4x4' Handy Boxes, but that's easy to improvise.

It should be noted the Clamp Combo Connectors come in various sizes and you need to match it to the hole in the electrical box you plan on popping out.

I ended up using a Lava Lamp for testing and remembered the comments about an indicator lite. Well it's not pretty or efficient but it's very easy and gets the job done if that's a feature you desire.

[bluize70]

I can't tell in the pics if you have done this but the ground wire should also be connected to the 'handy box' which in turn would be grounded thru your outlet which is ground thru your breaker panel...the way it is now if something went wrong inside it would be looking for a good ground which could be you...

[MuadDweeb]

The ground terminal on the outlet is usually attached to its mounting points. When you screw the outlet to the cover and the cover to the box, the box should be grounded if you have paid attention to the rest of the instructions. (i.e. green wire from your power cord going to the outlet ground connection.) I did one of these a long time ago with a few refinements... not sure if I should submit my own 'ible or if I should just post the enhancements here... What sayeth the collective?

[milsorgen]

 Do your own instructable, threads have a way of going zombie and the relevant info is lost for most.

[Pauper]

No ... since the ground wire is connected to the outlet ground, and the outlet is mounted to the outlet box by the mounting screws, the box IS grounded thru the outlet ground. The mounting lugs on the outlet are at ground potential. This is standard code for electrical wiring.

[222fbj]

How to measure/mark temperatures on the dimmer? An inexpensive hi temp thermometer?

[milsorgen]

 That's what I was thinking, or just assume that half way is half power and hence half the normal operating temp of your iron.

[bruno85]

can you just use a normal off or oon light switch or the one you have

[ScubaSteve]

This is so you can control the temperature of your soldering iorn.

[mightywombat]

I was thinking of doing something like this too, but some dimmer switches work differently than others.

[linstonsequeira]

 cooooooool instructable.....................................................................................................................i was thinking of somethin like this.....................................

[TCPMeta]

No wonder why America lost interest in Australia in the mid 90s, to many stupid laws. Anyway, great instructable. I've been thinking about this for a couple of years and didn't really think it would be worth to try but after seeing this and still ticked off at blowing up my last circuit I might try this project ASAP.

[hoihoi151]

You do realise it is illegal to do electrical work on mains power operated equiptment??? You need an electrical license first.

[Gamernotnerd]

No, it's not.

[hoihoi151]

it is here in australia

[zomfibame]

man, that sux. most of the best education I've given myself in this life is from working on or with electric stuff that is part of the main or plugs into the main. I wonder how many thousands of dollars I've saved myself by doing my own electric along the way.... I also wonder how many times I'd have gone to jail by the time I was 13 or 14 if I had been born in Australia? ;-)

[Gamernotnerd]

You should have specified that.