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Old 17th July 2003, 09:21 PM   #1
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Default Crossover soldering question

Hey guys,
I'm getting ready to put together the crossover for my AV2 center channel, but I can't for the life of me think of what the right way to solder the foil leads of the inductor to the leads of the caps, or the speaker wire. If you guys could just tell me the ways you've used and been successful with it would be greatly appreciated. Thank you for your time.

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Old 18th July 2003, 12:21 AM   #2
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Mike arrange the components neatly on a thin board say a 1/4 inch or so thick and point to point solder the leads together silicone or hot glue works good for the caps also tie wraps for the inductors

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Old 18th July 2003, 10:10 AM   #3
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I lay the leads perpendicular to the foil, folding about 1/2" of foil over the lead and then folding the foiled lead over to crimp it all together. A little solder and you're done.

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Old 18th July 2003, 11:40 AM   #4
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Coils(if you have more than one) should be at 90 degrees to eachother so that their fields interact less. This does mean that only one will be flat on the board, with the others upright, but cable ties or hotmelt glue will secure them.
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Old 19th July 2003, 03:33 AM   #5
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I use a blowtorch for big soldering rather than a soldering iron which, I'm thinking, is not designed for such big pieces of metal as our foil inductors. Now I just use the blowtorch for everything, being careful not to get things too hot. Use a small blowtorch of course; one of them small 5 or 10 dollar ones.

Maybe I'm misunderstanding your question. What do you mean by right way?
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Old 19th July 2003, 04:56 PM   #6
greg7 is offline greg7  United States
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I used a foil inductor on the bass in my diy speakers and what I did, based on advice from Danny at GR Research and Dave Ellis was to poke a hole in the foil leads and thread the cap leads, wires, etc. through said hole, bend the lead parallel with the foil lead, twist, then solder the whole shebang on both sides. The other advice given to you on this is also pertinent and important (inductor geometry considerations, tie leads, hot glue / silicone, etc.)
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Old 19th July 2003, 06:03 PM   #7
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Thanks a lot for the input guys. greg7's tip was exactly what i was looking for, makes sense now too. As far as inductor orientation is concerned, I only have one inductor in each my woofer and tweeter crossover sections, and those are going on seperate sides of the enclosure, so I'm guessing they will be fine. In my last project i used hot glue to secure the caps and resistors to my crossover board, and now about a year later some of those have come loose and are just hanging there by their soldered leads. So needless to say, I used wire ties to secure everything in these crossovers. Thanks again for the input guys.

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