Phil, I guess the few simplest ideas left that I have are as follows: * Prep the axial leads with a frog leg bend so the part will be above the surface after installation prior to soldering * Prep the part with one frog leg bend and mount the part with the u-bend if you have height clearance * Sleeve the body with heat-shrink sleeving prior to installation * Dip the body of the part in Type UR Conformal Coat per IPC-CC-830 There are others, but you seem to have reluctance at doing anything to the bare printed board. Dewey -----Original Message----- From: TechNet [mailto:[log in to unmask]] On Behalf Of Craig Cullum Sent: Friday, August 17, 2007 7:21 AM To: [log in to unmask] Subject: Re: [TN] Solder mask as an insulator - illustration posted Aaaaah. I've experienced something similar in the distant past when hand-assembling prototypes and such. The cover (epoxy?) of metal-film through-hole resistors is not as structurally sound as one would presume. Craig Cullum, Engineering Technologist, AMTELCO e: [log in to unmask] [log in to unmask] f: 608 838 8367 v: 608 838 4194, or 4197, x128 Please visit us at www.amtelco.com > -----Original Message----- > From: TechNet [mailto:[log in to unmask]] On Behalf Of Phil Nutting > Sent: Friday, August 17, 2007 7:15 AM > To: [log in to unmask] > Subject: Re: [TN] Solder mask as an insulator - illustration posted > > Good Morning folks, > > I created a graphic to illustrate our "punch through" problem > as I don't have any photographs of the failed board/part. > > Steve Gregory has posted the illustration at > http://stevezeva.homestead.com/files/LPI_punch_thru.jpg. > Thanks Steve. > > Phil --------------------------------------------------- Technet Mail List provided as a service by IPC using LISTSERV 15.0 To unsubscribe, send a message to [log in to unmask] with following text in the BODY (NOT the subject field): SIGNOFF Technet To temporarily halt or (re-start) delivery of Technet send e-mail to [log in to unmask]: SET Technet NOMAIL or (MAIL) To receive ONE mailing per day of all the posts: send e-mail to [log in to unmask]: SET Technet Digest Search the archives of previous posts at: http://listserv.ipc.org/archives Please visit IPC web site http://www.ipc.org/contentpage.asp?Pageid=4.3.16 for additional information, or contact Keach Sasamori at [log in to unmask] or 847-615-7100 ext.2815 ----------------------------------------------------- --------------------------------------------------- Technet Mail List provided as a service by IPC using LISTSERV 15.0 To unsubscribe, send a message to [log in to unmask] with following text in the BODY (NOT the subject field): SIGNOFF Technet To temporarily halt or (re-start) delivery of Technet send e-mail to [log in to unmask]: SET Technet NOMAIL or (MAIL) To receive ONE mailing per day of all the posts: send e-mail to [log in to unmask]: SET Technet Digest Search the archives of previous posts at: http://listserv.ipc.org/archives Please visit IPC web site http://www.ipc.org/contentpage.asp?Pageid=4.3.16 for additional information, or contact Keach Sasamori at [log in to unmask] or 847-615-7100 ext.2815 -----------------------------------------------------