Cuttin down a flexshaft?

[Titzwhip]

I've never cut down a flexshaft before, so what's some tips and tricks?

[Doby]

A decent Dremel tool and a cutoff wheel..measure twice before cutting.

[rickwess]

I've been practising tonight.

A dremel with a cut-off blade works well. I then squared off the cut and deburred using a workbench belt sander. Then using my 60 watt Weller soldering station I soldered the last 1/2" of the shaft.

The trick with soldering is to use plenty of flux and clean with rubbing alcohol afterwards.

[nemz305]

i agree with rick use a dremel then debur with a belt sander or i use various files then dip the end in flux let the shaft sit on the solder gun and let solder seep into the groves i clean everything with 90percent alcohol aswell

[Titzwhip]

Thanks guys!

[kfxguy]

I cut mine with a dremel. Then I set my tig machine on 10 amps and went around the tip of it and melted the wire so it doesnt fray.

[Titzwhip]

Yeah I could tig weld it it'd be faster than waiting for the soldering iron to heat up haha

[siberianhusky]

I do the same thing with a mig welder, much easier than soldering it. I like the fact I can keep all the heat at the very tip, don't have to worry about changing the temper where it matters. As opposed to a torch and silver solder.

[rickwess]

I do the same thing with a mig welder, much easier than soldering it. I like the fact I can keep all the heat at the very tip, don't have to worry about changing the temper where it matters. As opposed to a torch and silver solder.

No need to use a torch. A 60w soldering iron is more than enough.

[siberianhusky]

That's what I used to use, then I bought the welder. A lot of people I read about head for the torch when they have problems with getting the heat into the cable using a small iron for electronics.
LOL I have 3 different irons of different wattage so I can select the appropriate size for the job.

[electric]

Others will shoot me for saying this, but after a few failed attemps to solder my shafts I have not soldered any of them and none of them have ever failed or frayed. I know you should cap the end with some solder, but just sayin'.

[rickwess]

If that works for you, great!

For soldering, I found that you really need to be liberal with the flux. Just out of habit (from soldering copper pipe) I also do a light sand on the area I plan on soldering. It takes about 10 seconds to complete a solder job with my 60w soldering station. I'm convinced a 40w iron will work as well.

I know people are worried about rust, because flux residue is nasty on metal so just dip it in rubbing alcohol a few times and wipe it down. After cleaning, the grease you use will keep the flex shaft in great shape.

I actually thought it would be a much tougher job based on the commentary I was reading on this site, so I did order a 80w iron from Steve. It's still unopened.

[Rocstar]

I have not soldered any of them and none of them have ever failed or frayed. I know you should cap the end with some solder, but just sayin'.

Agreed.