This is a soldering iron that I made from parts that I found around the house as well as tools that I had lying around. It is a relatively simple way of creating a tool that could be used on the go for electrical needs. This came about when I needed a way to complete the electrical work that I had wanted to do but did not have a soldering iron already at home for use.
Step 1: Tools and Parts
- Wire Strippers
- Wire Cutter/sharp tool to cut the copper cable
- Scissors (for electrical tape)
- Screwdriver (only to make a hole in the wood without drill)
- Electrical Tape
- Hot Glue Gun
- 3 Wood Blocks (Mine from Jumbling tower board game)
- 18 Gauge wires
- AA Batteries
- RC Battery Box
- Hair Dryer (I had one at home)
- Bare Copper wire (8 Gauge)
- 18 Gauge Red/Black Connector Wires
Step 2: Open Dryer for Parts
- Open dryer to reveal the coils and wires on the inside
- Remove one of the coils as well as some of the covers by cutting the wires and extracting
- Leave the rest on the side as it will not be used anymore.
Step 3: Prepare Handle/Mount for Copper
- Take one of the wood blocks and drill a hole on the top side (smallest ends) about the size of the copper wire (1/8 Inch Diameter) 1 inch into the block.
- Cut the bare copper wire to roughly 1.5 inches in length
- Push bare copper wire into the hole and secure tightly (should stick just by being in the hole).
Step 4: Assemble Base
- Assemble the base using 3 wood blocks
- Connect 2 wood blocks together on the long sides using hot glue
- Attach the last wood block with copper wire in it on the top (short side) again with hot glue
Step 5: Connecting Wires to Battery Box
- Use the RC car batter box and find positive and negative ends that are eligible for connection
- Connect red and black wires to positive and negative ends respectively
- Be sure that the wire is connected to inside in order to get proper connection
- Wrap outside in electrical tape to secure and hold it together
Step 6: Setting Up Copper Wire
- Take the protective cover and cut off enough to cover the wire while leaving the end exposed
- Slide the cover all the way down the copper rod
- Take roughly 5 inches of the nichrome wire that was extracted earlier and wrap around the protective cover
- Leave enough of the nichrome wire sticking out on either side to wrap around the other wires later
- Try to keep the coil tight against the covering when wrapping
Step 7: Connect Nichrome Wire to Battery Box
- Take nichrome wire and battery box
- Connect red wire to one end of the nichrome wire and black wire to the other end of the nichrome wire.
- My battery box already had a switch on it but can attach one on if you don't
- Again wrap tightly to get proper connection and to complete circuit
Step 8: Final Touches
- Here you can secure the battery box to the 2 block section of the base with hot glue.
- You can as well wrap electrical tape around the 2 wires and bind them to the single block section of the base.
Step 9: Good to Go
Just place in the batteries and switch on the device. Be sure to let the device heat up as it takes a while before it is hot enough to melt the solder and is usable.