All,

I am looking for empirical data to support the following:

A through hole component (5 leaded) is to be installed on the solder side   
(all other components are on the component side of the board except this   
5 leaded component) of the board being hand soldered from the component   
side of the board.  The 5 leads (0.020 square lead in a 0.035 diameter   
hole )coming through on the component side has about a 0.200 inch   
clearance around them for clipping accessibility.

Is there a way to get a reliable solder joint of the through hole leads   
when the leads are clipped, after being soldered by hand,  very close to   
the surface of the board, say 0.020 inches to 0.010 inches or less?  Does   
the clipping through the solder fillet cause a reliability issue with the   
solder joint?

The reason for having the leads clipped flush is because there is a part   
of the plastic enclosure coming very close to the leads and this would   
cause interference between them.  I would appreciate any useful   
information to resolve this issue.  Could the leads first be cut to   
length then be soldered by hand in some way?

Thanks Much,
Greg Kaskey
Senior PCB Designer
Checkmate Electronics, Inc.
770.594.6000 x228
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