Hi Doug Bit of TLA burnout here, [using 2 in combination is too much], what is DLO/RHH wire? You say similar to welding wire but what I Googled was tinned copper braid wire with a high temp insulation. I work 1 AWG to be 7.35mm [0.29"]. So if you are looking at tinned copper braid, the UL guy is being a bit picky. From a strict soldering point of view this is nothing that special - Possibly the polymer insulation and stuff might affect the process limits. Tinned copper should not be a special challenge! If you have to use a separate flux, use the least active that works. Type R would be most likely be OK. Take care not to get wicking of flux solder up the braid [as usual]. If it is solid welding rod then the UL advise is good. You will probably need an active [water wash] flux and wash off [depending on the precise composition of the rod.] This will pre-tin the surface making it solderable by puny electronic grade assembly fluxes. Regards Mike -----Original Message----- From: TechNet [mailto:[log in to unmask]] On Behalf Of Doug@lcm Sent: Friday, October 22, 2010 11:03 PM To: [log in to unmask] Subject: [TN] Any recommendations for solder alloy to tin DLO/RHH flexible wire?" The company I work for wants to use DLO/RHH flexible wire ( very similar to welding wire) in the electric control panels we build. The UL inspector has informed me that in order to do so we have to tin the ends of the wire (AWG 1/0 and larger) he said that some of the panel shops he covers use a solder pot to tin the wire. I contacted Kester and inquired about the best solder and method to use. The engineer that replied suggested I contact IPC forum and inquire. So here is my question. What is the recommended solder and if needed flux to use to tin the ends of this flexible wire? Douglas Minniear Lewis and Clark Machine P.O. Box 615 501 Lottery Ln. 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