Soldering - inability to avoid cold joints

Have you tried an alligator clip?
Kind of past that now. The wrap and the bad joint was enough to give the same resistance as the other lead, and it charges the battery fine (they only charge at up to 10v, 3A).

It’s more for the skill building and some other things that I know I need to solder.
 
That lug looks like it's designed to be clamped around the wire. Is that way still possible? What you're doing seems destined for failure.
You should have seen the original connection. Just the wire laid on the lug, a blob of solder. The wire fell off and the pad of solder was just a perfectly flat smooth surface.

OP seems to be asking future as well. Lifetime investment but reall a super skill improvement. I have a Hakko 936, I paid $80 new in 2009. Now they have some real watt beast China knock offs for less.

FTR I trained at China Lake NWC. I was a certified solder process examiner for many years
Exactly!

Years ago I could not get some half inch copper plumbing pipes to solder no matter how many times I tried. I just happened to buy some new soldering paste as a last resort. Instant success! The old paste in my plumbing kit had turned a dark brown, the new paste was light amber colour.
It's was like the old paste had turned into solder repellant.
Interesting! So fluxes may have a shelf life?

I know the flux would melt and flow. Saw that happen easily.
 
60-40 should be okay for your work. I will throw a few things to watch out for.
The two mating surfaces must be nothing less than perfectly clean. Flux will not clean tarnish.
Both parts must be at temperature for the solder to wet. If one acts like a heat sink it'll be impossible to wet it. I have problems soldering wires to chasses when I restore old radios because the chassis acts as a big heat sink. (I'm guessing this may be your problem)
I've used old flux before... like decades old, so I doubt that is a problem.
 
Kind of past that now. The wrap and the bad joint was enough to give the same resistance as the other lead, and it charges the battery fine (they only charge at up to 10v, 3A).

It’s more for the skill building and some other things that I know I need to solder.
General priciples - I apologize if these are too simplistic.

Clean soldering tip! Tinned. Make sure the solder is appropriate (i.e. no plumbing solder for electronics). The tinning on the tip is the first heat pathway to the joint.

Setting up the fixturing of the parts is usually the most complicated part of the job, and can be an art in itself. As said ealier, you don't want them to move.

There must be physical contact between the parts. Since you often can't touch them all at the same time with the tip, heat needs to flow between them. In my experience, the flux is very helpful in facilitating heat flow.

Never use the tip to "dip" solder onto the work. This seldom works.

Do use the tip to try to evenly heat all the parts. The solder follows the heat. No heat, no solder flow. After fixturing, heat flow should be your primary area of focus. Note - this would also apply to soldering plumbing copper with a torch.

Once solder is where it needs to be, do not disturb the joint.

It's best practice to clean off the visible flux, and is usually required for professional electrical joints.
 
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Those are all 65-75W it seems. I can’t heat this enough with 140.

Heat sink, I get it, but still want to figure how much heat I really need….
There is more to soldering than raw wattage rating but yeah some look weak

https://a.co/d/03yGPdeD

Soldering demands high heat fast to a fairly fine point and little temperature drop while transferring the heat. Solder guns are slow and not particularly heat concentrated
 
This is a better choice than that big vise

Screenshot_20260703_205121_Chrome.webp
 
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Interesting! So fluxes may have a shelf life?

I know the flux would melt and flow. Saw that happen easily.
Yes. I was going to reply in agreement.

A couple of years ago I was working with some 1" copper & fittings and kept getting crummy joints, despite thorough brush and flux prep. I was using run-of-the-mill Oatey flux that I'd had for years. Just for giggles I bought a new tin and as soon as I applied it I saw a huge difference. Where the flux was on the old, oxidized pipe (past the cleaned area) it turned bright and shiny when hit with my torch. The old stuff didn't. All subsequent joints were excellent.

I mentioned it to a plumber and he said he hadn't seen that, but he never used 25+ year old flux 😄
 
Are the newest ones that bad. Reading the reviews it looks like the quality has gone down the drain now but mine is an older one.
I don't know. I've never had any success with them new or old. I can't stand them. They heat up fast and transfer no heat to the joint. I don't get it. I like weller products, and my main iron is a weller. But those guns are a joke.
 
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