Busbar help needed


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TheStealth

New member
Joined
Oct 29, 2020
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Hi, I need some help attaching my busbar to my battery packs built using fused nickle. I tried a 100w soldering gun and a piece of rebar heated with a propane torch, but still can't get enough heat to melt any solder. The copper just sucks away the heat too quickly. Any tips on how to get this done?
 

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I sure hope you didn't heat the bus bar while it was on the packs.

Soldering to copper like that you need a much higher wattage iron, and/or you need a massive heatsink on the iron
Something like these:
1756909147903.png


You can kind of do this yourself if you take some bare wire and wrap it around the iron to build up the heatsink. This will just take longer to build up heat, obviously. The other is to use a fat tip, like 3158 and higher shown above as well. You might be able to make one yourself, or if your tip is long enough, wrap some bare wire around it as well.

The trick is to provide plenty of heat to transfer. A standard iron just can't do it as it can't keep up.

The other is to go with a higher wattage, like 250w iron or better.

And ultimately, the *best* option, is to spot weld the wires to the busbar. Takes a little getting use to, but that's the best option. You won't be wasting a lot of time and [literal] energy trying to solder the wires.
 
And ultimately, the *best* option, is to spot weld the wires to the busbar. Takes a little getting use to, but that's the best option. You won't be wasting a lot of time and [literal] energy trying to solder the wires.
Interesting, never thought of spot welding. Since I have one, what is the process like? Any suggested how to Videos?
 
I'm not sure of any off hand. I haven't done spot welding on bus bars. I know others here have done quite a few spot welding bars, maybe they can chime in their experiences and tips/tricks on how to get a good one.
 
Last edited:
big assed soldering iron and GOOD flux & solder
 
May be prepare those bars in advance..
In this case you can preheat them with hot air gun.
I routinely solder 6awg twisted wire copper bus bars on my packs with 100w iron. Great idea to pre-solder both the buss and the nickel plate and then place the buss on so the pre-solders line up and then apply some heat / solder so they flow together. The pre-solder blobs will help with heat transfer as they already encase the buss etc.
 
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