I got an old weller soldering gun ( iron ) from the dump, but the tip was shot. Easy to buy a new tip, but I thought the replacement tip was too expensive for a gun that cost nothing. But without a tip what use was the gun? So how to make a replacement? A free replacement. Here is how I did it.
Step 2: Procedure
It looks pretty much like the tip is made of copper wire, and I had some wire that was similar to the tip. This wire came from the salvage of romex house wiring, you can do this by clamping one end of the wire in a vise and use a box cutter or knife to slit the outer insulation. Individual strands can be stripped in a similar way. Bend the wire to shape as show in the photo. Slip the old nuts from the old tip over the wires and bend L's into the end. Screw back into the gun and you are done. I made sure the part of the tip that would be used for soldering was well tinned with solder, this helps to protect it from corrosion.