Fixing 3/16 square copper

nisse · Nov 16, 2015

I recently picked up a Miller DC converter
that was part of a package deal with the
welder I wanted. I didn't have much luck
using it so I opened it up and found the
square copper going to the positive lead had
been repaired in the past with solder and a
battery clamp, and it had come apart again.
I would like to try to repair it, any
suggestions on the best method? I have
soldered wires and pipes but not sure how it
would hold up. I have very limited
experience with silver solder years ago, but
was thinking that might be a good option?
Thanks,
John

NCWayne · Nov 17, 2015

Solder, regardless of the type, will eventually melt given the right heat.

To fix it right, find someone with a TIG welder, and let them basically weld/melt it back together, copper to copper.

K-Mo · Nov 17, 2015

Can you get enough material to overlap the ends and fasten it with a small Split Bolt Splice Connector?
Clean it to bare copper and then coat it with shellac after repair to prevent corrosion.

Indiana Ken · Nov 17, 2015

Are you sure it is copper rather than copper coated aluminum? Might put a file to it and verify the center is indeed copper colored.

For repair I would consider some sort of crimp on cable splice sleeve. If it is aluminum I would expect it to fail again.

da.bees · Nov 17, 2015

I would bend 1/16th copper into a 3 side box overlapping both pieces as much as possible then solder in place. Lay a 1/8th piece on open side of box and clamp in place. The idea is maximizing contact surface to miniumize resistance at connection.

Bob · Nov 17, 2015

You nailed it, Ken, it is aluminum.

dr sportster · Nov 17, 2015

That sure looks like aluminum corrosion. If you have enough of a tail sticking out you could bug a piece of copper wire in there . Bugs are mechanical connectors from electric supply houses that squeeze the connection tightly together.They require insulation when done.

dr sportster · Nov 17, 2015

scroll down to where it says copper bug.
Untitled URL Link

nisse · Nov 17, 2015

Thanks for all the replies, I did go check, and it is aluminum. I like the idea of a connector, but the one end is pretty short and there is isn't much room. It looks pretty easy to take the transformer out, I'm thinking I'll have to do that for any repair.
Thanks,
John

Fixing 3/16 square copper

nisse

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NCWayne

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K-Mo

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Indiana Ken

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da.bees

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Bob

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dr sportster

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dr sportster

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nisse

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