Twisted Pair Wiring Repair

Durability of a wire splice is dependent on getting a joint that does not oxidize. Soldering is effective in keeping the air (oxide) out of the joint electronic circuits. Very high current circuits may fail because of oxidized joints that are not visible with the naked eye.

Durability of a splice is also dependent on keeping the moisture out of the joint. Heat shrink tubing alone won't do it. The tubing must contain a "hot melt wax" which is squeezed from the ends (both ends) of the tubing during heating and forms an adhesive seal between the wire insulation and the tube. Use the following procedure anytime a twisted pair circuit is repaired.

1. Correctly strip the wire. See Fig 1 .
   Fig 1: Determining Proper Length Of Strip Wire

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2. Twist and solder the wire. Use resin core mildly activated (RMA) solder. Do not use acid core solder. See Fig 2 .
   Fig 2: Twisting & Soldering Wire Properly

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3. Form (bend) the circuit into shape for sealing. See Fig 3 .
   Fig 3: Positioning Wire Properly For Shrink Tubing

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4. Reposition shrink tubing over splice. See Fig 4 .
   Fig 4: Positioning Shrink Tubing

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5. Heat the entire length of the shrink tubing until the "hot wax" comes out of both ends. When the "hot wax" flows out of both ends, remove heat. See Fig 5 .

Fig 5: Identifying Hot Wax & Proper Shrink Tubing Heating

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