Wire-wrapping is a method to connect wires to pins that requires no soldering. Wire wrapping tools can be expensive. I just discovered a way to make decent wire wrapping without purchasing the expensive tool.
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Step 1: Materials
- Empty ball point pen ink cartridge. The one I used has a outer diameter of 3 mm and inner diameter of 2 mm.
- Utility knife
- Anything that has a needle on it.
Step 2: Cut the End
Make sure the end of ink tube is smooth. If not, cut it.
Step 3: Pierce.
Pierce on the wall near the end of the ink tube. The hole size needs to allow the stripped wire pass through.
If you want to use this tool on a electric drill, cut the tube to appropriate length.
Your $0 wire-wrapping tool is done!
Step 4: Wrap.
lock the tool into the chuck.
Pass the stripped wire (about 1 in long for AWG 24 on 2.54mm spaced pin) through the hole you pierced from inside of the tube to outside. Make sure some of the insulated part is in the tube.
Put the wrapping post (the pin) in the center of the tube. Push the tube/pin all the way in.
Put the drill in forward. Pull the trigger. Or twist the ink tube by hand.
The wire should be wrapped on the pin.
Step 5: Bugs
Wikipedia said the copper part needs 7-9 turns, which is easy to accomplish with this tool and proper stripping length. However the insulated part needs 1.5-2 turns, while my tool can only do 0.5 turn (maybe you can manually wrap the insulated part before inserting the wire into the tool). But according to my experiment, bare metal part is unlikely to touch anything else even if the posts are adjacent.
Another problem is the short life of the tool. After about 20 wrappings, the hole will become a wide crack. But all you have to do is cut off the worn out end and pierce a new hole.