Like the Jedi of the Old Republic who constructed their own lightsabers, each customized to the needs and style of its owner, many Instructables members build their own soldering irons, or at least heavily modify them. Last time I checked there were approximately one jillion instructables on the subject of homemade soldering irons.
A well constructed lightsaber is, according to Wookiepedia
, a Jedi's "single perfect weapon that he or she would keep and use for a lifetime."
If only I had such a "perfect" soldering iron that would last forever! In my experience, soldering irons are reliable enough, but far from perfect. The part of the iron that is consumed the fastest is the tip. Soldering iron tips wear down, burn up, diffuse into the solder, or something... Honestly I'm not certain where the mass of the tip goes. Intuition, and the law of conservation of mass+energy, tell me it has to go somewhere. Everything goes somewhere.
Anyway, all I know for sure is that I start out with a perfect well-tinned tip like a shiny sharpened pencil, and several hours later I end up with a crusty burned-looking stub. Hence the motivation to replace the tip every now and again.
The soldering iron tips created in this instructable are made starting from 6 AWG solid copper electrical wire, and these tips are are approximately 4 mm (5/32 inch) in diameter. In this instructable, I show how to make two styles of 4mm tip, the slidey-style, and the screwy-style.
Step 1 takes a closer look at these two styles of soldering iron tips.