As promised, here is the SBS on how I went about soldering up these slat armor arrays. First off my tools:
From center clockwise, Flat nose smooth jaw pliers, #11 blade, needle point tweezers, narrow smooth jaw pliers, metal snips (on top of the others) poster tac, soldering iron, flux, and solder. I do all my soldering on a small glass plate so I can turn the whole assembly as needed. The ceramic tile is to place the soldering iron on so I won't burn my cutting mat.
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This is the head I use to solder with. It is actually a wood burning tip, but the point is so fine it works great with this small stuff.
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Initial layout of main support is held in place by poster tac. This helps as the parts won't move around when installing the subsequent pieces.
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Remaining pieces have one end lightly dipped in flux and inserted into their respective slots. The solder serves two purposes; it acts as an adhesive and keeps the part in place, it readies it for the follow on application of the solder.
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All slats have been installed on one end and soldered in place. The comb looking tool keeps things straight and level.
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The opposite end piece and remaining slat lengths are added and soldered into place. More poster tac is used as a heat sink to draw heat away from already soldered joints.
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The vertical rods are added. one end of the rod is soldered in place....
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The alignment tool is used to evenly space the slats and the opposite end of the rod is secured and then cut.
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The remaining rods are installed in the same fashion.
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Once all the rods are in place, the alignment tool is used to keep all the slats even, and then the slats are soldered to the vertical rods thereby making the whole assembly very strong. This is hard to do using super glues...
After all soldering is finished a grinding stone is place in the Dremel and all soldered joints are cleaned up.
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The last thing done is to use a medium grit sanding stick and run it over the entire assembly and finally rinse off the flux residue with some lacquer thinner.
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I hope this helps. If I can do this, anybody can.
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"Q"
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ps. The key to all of this is the glass plate and the poster tac. The tac acts as a heat sink and it also keeps things in place. The glass lets me rotate the pieces for easier access rather then laying things out so I can get to them...