How to Do a Western Union Splice





Introduction: How to Do a Western Union Splice

This the solder splice that offers the least resistance I've ever found : less than a hundred micro ohms! My Ohmmeter doesn't read less than that, so I'm happy with it.

It's quite easy to do and offers great mechanical resistance for virtually no electrical resistance :)

Step 1: Wire Wrapping

First you want to remove a good 5 cm (2 inches) of insulant on the wires, then twist them on themselves to make a single thick brand.

There's a great scheme here that came from wikipedia and sums up the following:

1) Fold in the middle and give one or two turns

2) Wrap tightly around the other wire using pliers or your fingers if you feel strong today

Step 2: Drown It in Solder

Finally, heat the wires with the tip of the soldering iron and then apply the solder by touching the wires with your soldering wire.

Once the whole thing is soaked in solder, you're done!

You can easily slide on a piece of heatshrink and the splice should withstand the strongest of tugs while guaranteeing incredicle electrical contact.



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    Use detail "D" with no solder. IF wrapped tightly, ZERO air will get between the wires (non visible part. Solder WILL provide a Breakpoint - at each end! This splice is well over 100 Years old and works every time - IF TIGHT! There is also a "T" splice also. I have provided many links to this, for many years. Search; "Western Union Splice" and/or "W.U. Tee Splice". Soldering needs to be quick - Use a Weller Expert (model 4100 for example) 100/140 Watt Gun. Clean tip, apply a bit of rosin core solder THEN touch the wire, add a bit of solder. remove gun. Antennas and wires that move or are in Tension, should NOT be soldered! As that is were the break WILL OCCUR. I've used this method - since 1957 - wires are STILL shinny, where they were TIGHTLY wrapped = virtually ZERO OHMS. NASA approved!!!

    There is also this Heatshrink solder splice connector. Heat shrink tube with solder inside. Only ever used it when I was training 40 years ago.

    Remember to slide enough heatshrink tubing onto one end before soldering, or use heat shrink tape.

    Let it cool before you slide the heatshrink on, otherwise it will shrink before you get it in place.

    Chill bro, this is s a place for learning, and some folks might not think of this little "Gem" that GeoffN4 dropped on us. A lot of folks don't have your years in soldering and electronics, I do, but not everyone has.

    Thank you. Took the words right out of my mouth. I didn't know about this before, but I'm thirsty for knowledge! ? Soldering.....I think in Girl Scouts we used a soldering gun. But for sure once or twice in middle school technology. ? Thanks to anyone with constructive criticism and willingness to share your knowledge. ????

    Wait a second...did you just say that there's heat shrink TAPE? I've only ever seen/used the tubes. Where can I find the heat shrink tape? I prefer the tubes, but there have been a few times when the tape would have come in very handy!

    Nice *ible* by the way!

    Been doing my splices like this since high school ? and that's going back more than just a few decades!?

    Here is an example