Hey'a Stephen !
Didn't know you swamp Cajun folks with alligators to amuse you do
actually know anything about proper "ol crusty salts" living on a steady
diet of american tourists (no terrorist dares to come around - pity) up
in Territory ;
but it seems you hoal in the right direction :
Save you this time in return mate :
1
Under NO circumstances you degrade your tech reputation by using of
crude and unrefined methods of "dremel" solutions :
you break the barrel ; twist rip the pads ; bloke in question does not
deserve daily bread in this industry .
The sight of twiddling pad on drill bit is most disheartening !
2
Under NO circumstances you thermal shock those poor little bugs :
unless you know the internal construction well enough ; the bloke in
question should be blasted with CO2 to get the feel of it .
X
THE solution :
Take a just undersized needle , plunge it half way in and GENTLY vigle
it in full circle (a knob on the end of helps, without going to details)
.
The point is most of drilling folks for economy reason do not use any
supersharp drills all the time ; so you have a relatively soft hole core
into which you can massage the copper barrel (being pretty hairy on the
outside anyhow it just beds nicely in) .
Also the hourglass profile (how on earth did I get myself into answering
this puzzle) does help a lot on the insertion as the top half open
facilitates the placement and the bottom half takes the solder
sufficiently as you usually have a little chance (with round legs ;
better with square legs) for the proper top flow wetting to get through
the waist of the massaged barrel .
Did it hundreds times ; trained same No. of operators ; coppers
maleability is a dream .
See you Steve ; refreshing to have around .
paul
> ----------
> From: Stephen R. Gregory[SMTP:[log in to unmask]]
> Sent: Tuesday, 25 August 1998 11:57
> To: [log in to unmask]
> Subject: [TN] Assy: How can a square peg fit in a round hole?
>
> Hi ya'll!
>
> I'm pretty sure that one or two of you "ol' crusty" types (I mean that
> in a
> GOOD way), have run across this problem I have a time or two. I have
> this
> board I'm building in a quasi "prototype/pre-production" run that has
> a PTH
> rectifier diode installed vertically...some of you have may have
> guessed what
> my problem is already from my subject, the hole's too small.
> Lead diameter is right around .050" +/- a mil or two, guess what the
> hole size
> is? .050", +/- a mil or two...that's just peachy ain't it? It goes two
> times
> per board, and we gotta' build a hundred of these, maybe two hundred.
>
> So tell me, what have all you "old salts" done to make a square peg to
> fit in
> a round hole? I've had some REALLY GOOD suggestions from some
> "experts" here,
> one was to get a dremel and drill the hole out (sounds good to
> me!...snicker),
> another was to get a can of "Freeze-it" and spray the diode leads with
> it,
> then hurry up and stuff it in the hole before it warms up and
> expands...that
> sounded pretty keen too, except it's hard to hold the diodes when
> you're
> wearing mittens to keep from getting your digits frostbitten.
>
> So I told my "helpers" that I really appreciated their suggestions,
> but that I
> would like to give the technet a chance to offer some guidance to me,
> and that
> no-way were the suggestions from the TechNet going to be as good as
> theirs,
> but I wanted to see what popped up...and I would come to them if I
> needed
> anymore "help"...in other words, don't call me, I'll call you.
>
> I'm sure glad this is email, it would be kinda' hard to carry on this
> conversation with my tongue in my cheek like this...
>
> So, what's the verdict? Am I hosed? I looked around on the NET trying
> to find
> the same spec'd diode with smaller lead diameters, but no joy. The
> only two
> companies I found were Motorola and General Instruments, and they both
> listed
> the same thing that I have now.
>
> Is there any trick that any of you have done to make something like
> this work?
> I'm afraid if I don't figure something out, I'll be in mittens
> spraying diodes
> with freeze-it on the production floor...ya' gotta save me!
>
> -Steve "soon to be numb-fingers" Gregory-
>
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