Anyone have any suggestion how a guy with 10 thumbs can make 3-wire
end-to-end splices inside a small metal tube easily, reliably, and
reasonably fast?

R.Berglund

Spot welding is the usual method ... need it anyway so that
temperature doesn't soften solder joints.

SD


Should be easy to build a spot welder that size with a car battery.

Paul Lamar


Didn't think of welding them.  Might try that if current efforts fail.

Yes ... solder joints with pre-tinned wires is what I did on first two
trials. The stranded wire gets pretty fat when tinned. Then after all 3
leads are soldered they must be insulated from each other before
inserted into a small passageway (in my test-case, a hollowed out bolt).
I tried wrapping with small bits of tape.  I didn't have the correct
size of heat-shrink tubing in my junk box.

Tonight's trial involves filling a small soda-straw with epoxy and
letting it set up, then removing the small epoxy rod from the straw and
use it as a core for my wire-bundle, cutting three little longitudinal
groves in the rod to hold the wires spaced 120 degrees apart, apply
solder sparingly while wrapped tightly with aluminum wire to serve as a
heat-sink to protect the sensor as well as  keep the bundle as tight as
possible.  Then I can remove the aluminum wire, coat with more epoxy and
insert in the hollowed-out bolt. The epoxy-rod-core will remain inside
the sensor


R.Berglund