This instructable will show you how to take an inexpensive battery powered Soldering Iron and turn it into a slick USB powered Unbelievable Soldering Beast.
Step 1: Parts and Tools
Battery powered Soldering Iron, USB cable, Drill bit, Jewelers Screwdriver kit, Wire srippers, Soldering Iron and Solder
Step 2: Gutting the Iron
First, remove the battery cover, and any installed batteries. Next, look for at least two or three screws along the side that need to be removed. The model I have had two hidden screws underneath a sticker. After the screws are removed, carefully take apart the case being careful not to damage the wires connected to the Soldering tip.
Step 3: Preparing the cord and battery cover
First, take the batter cover and remove the original metal plate. Using the screw hole as your guide, drill a hole into the cover just big enough to snugly slide your cable through. I won't suggest a size because usb cables vary in size.
Next, Cut off the connector at the end of your USB cable leaving the male end of the connector intact. Slide the cable through the hole in the battery cover and move it low enough to give yourself some room to work. Now, strip the cable, shielding, etc. and expose the black and red wires and cut off any other wires in the cable.
Step 4: Soldering and assembly
Now, using a second (working) soldering iron, solder the black wire to the negative coil, and the red wire to the positive plate below the switch.
At this point, plug the usb cable into a computer or usb wall outlet and ensure you have a good working connection. If so, carefully re-assemble and enjoy your new USB powered soldering Iron.