Soldering wire to aluminum

eRiCdWoNg · 12th July 2004, 03:50 AM

Im doing a foglight project on my car and I am using the original foglight bulbs with the bulbs cut off as connectors. I tried to solder with regular solder but it didnt stick at all, so I'm assuming that its aluminum. How can I solder to aluminum to regular wire? Is it just aluminum solder?

dhaen · 12th July 2004, 08:00 AM

Well, check if it is aluminium. Ally is soft and consistent colour below the furface. Possibly it's not ally, but just some kind of plating that's stopping you. Filing through the plating usually works.
If you are soldering onto an automotive bulb, you might consider the temperature the thing will reach. I think some may melt solder on their contacts.

Normal solder does not work on aluminium because the aluminium creates an oxide layer immediately. Special aluminium solders require special preparation and higher temperatures, and most likely won't result in a good electrical joint.

eRiCdWoNg · 12th July 2004, 01:20 PM

I tried to file thru it, I used an angle grinder. Anyway, I think I have a new solution, im going to see if I can find some crimp connectors to put on there to mechanically join the connectors.

12th July 2004, 03:50 AM	#1
eRiCdWoNg diyAudio Member Join Date: Jul 2003 Location: maryland, USA	Soldering wire to aluminum Im doing a foglight project on my car and I am using the original foglight bulbs with the bulbs cut off as connectors. I tried to solder with regular solder but it didnt stick at all, so I'm assuming that its aluminum. How can I solder to aluminum to regular wire? Is it just aluminum solder?

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12th July 2004, 08:00 AM	#2
dhaen diyAudio Moderator Emeritus Join Date: Jun 2002 Location: U.K.	Well, check if it is aluminium. Ally is soft and consistent colour below the furface. Possibly it's not ally, but just some kind of plating that's stopping you. Filing through the plating usually works. If you are soldering onto an automotive bulb, you might consider the temperature the thing will reach. I think some may melt solder on their contacts. Normal solder does not work on aluminium because the aluminium creates an oxide layer immediately. Special aluminium solders require special preparation and higher temperatures, and most likely won't result in a good electrical joint.

12th July 2004, 01:20 PM	#3
eRiCdWoNg diyAudio Member Join Date: Jul 2003 Location: maryland, USA	I tried to file thru it, I used an angle grinder. Anyway, I think I have a new solution, im going to see if I can find some crimp connectors to put on there to mechanically join the connectors.