I've been thinking about doing this mod, and I've found this thread to be very useful (so thanks to everyone who has contributed)! That said, I worked in manufacturing, building high-end ribbon microphones by hand for a few years, so I've got pretty good soldering skills. With that knowledge, I'd like to address some earlier posts here, as I often see bad advice given when it comes to soldering.
First off, most soldering is pretty easy. I don't mean that there isn't any skill in it; there is, especially when you actually do get into very small/difficult jobs. If you're struggling, don't get discouraged. Part of your struggle is probably inexperience (we all have to learn to get past that), but another large part of it could very well be your tooling. From my experience, soldering difficulty comes from tooling as opposed to experience much more than many other forms of manufacturing / handy work. If you really are struggling, consider looking into upgrading your tooling, as it might not be sufficient for the job.
Here is some tooling and technique advice I can give:
I'll start with a big one that I often see people talking about incorrectly: There is NO SUCH THING as having an iron that is too powerful for a job. Any iron worth using for jobs like this will have some form of temperature control, and that's what matters. You may not be able to control that temperature without changing tips (more on that later), but the iron will have a target temperature, and stay as close to it as possible. The most important part of a soldering iron is how efficiently it can deliver iron to its tip. When you solder, heat is pulled away from the iron, so it needs to be able keep up with how fast that pulling of heat is occurring. The more power you have available, the more heat you can pull from your tip before you start running into issues. This is not only important when soldering large pieces of metal, heatsinks, large ground planes, etc., but even with sensitive components. If your iron can't keep up, you need to expose the component to heat longer. This will usually result in heating it up much more than using an efficient iron at a relatively high temperature, because with this better iron, you only need to apply heat for a very short amount of time.
So, anyone that tells you "don't get an iron that's more than X watts" is giving you bad advice. First off, as I said, that extra power just means you can get to a target temperature faster, and you can hold that temperature with more demanding jobs. Your iron will only use the power it needs to hold its target temperature. Second, even if your iron doesn't have any temperature control, it is better to solder at a high temperature for a shorter period of time than with too little heat for a longer period of time. To give you an idea of this, most industrial soldering (which is lead-free these days) is done at around 700°. That is clearly hot enough to damage things, but again, the soldering is done so quickly, that lower temperatures aren't needed for most components. Third, the power of an iron doesn't tell you how efficient it is, which is more important. Better irons usually put the heater closer to or inside the tip, and some of them use RF to generate heat instead of traditional heating elements. A 40 watt RF iron might be able to get hotter than an 80 watt traditional iron of a lesser design). I'll put some specific irons to look for below.
Second: Sticking with the irons, the tip you use can really affect how easy or difficult your work is. A larger tip will be able to transfer heat faster, but might be too awkward to work with. That said, if you are struggling to get enough heat into a joint, you might consider using a larger tip if this is an option (as long as it isn't bigger than what you are trying to solder, which won't help you). Also, the tip geometry can make a big difference. Most consumer irons come with standard conical tips. These tips work fine for general purpose soldering, but I have found chisel tips to be far easier to work with. The flat side makes it much easier to get a lot of heat where I need it quickly. That said, if you are working with very small components, even a small chisel tip might be a bit too large, so you might need to stick with conical. In addition to being able to reach smaller places, you can use any part of a conical tip, where as you might need to have room to rotate a chisel tip. Despite this, I rarely find myself using anything other than chisel tips for my own work.
Third: Having good quality solder matters as well. You're going to want something with flux in it. For lead-free, I like to use AIM Glow Core solder. You can get it in SAC305 or SN100C (different compositions). They have felt pretty similar to me, but I've never really tested them against each other in very demanding jobs. From the little bit of research I've done, most find SN100C easier to work with, despite having a slightly higher melting point. Apparently SAC305 is better at filling holes, but I still think SN100C is probably a better choice for general soldering. For leaded solder, I've found Kester to be fantastic. Both of these are very easy to work with, with leaded being a bit easier, largely due to its lower melting point. If you are working on vintage electronics, which usually used leaded solder, you should stick to leaded, as the mixture can lead to weak joints. For modern projects, if you have an iron good enough to handle lead-free, that's probably going to be a better choice.
With a combination of a good iron and solder, I don't often find myself needing to add any extra flux in addition to what's already in the solder, but don't be afraid to use it if you have to. When you need to get heat and solder to go where you want them to quickly, flux is your friend. I don't use flux enough to have tried a lot of it, so I just use whatever is available. I recommend cleaning flux off of joints with isopropyl alcohol when you are done, as certain fluxes can eat away at the joints over time.
Also, there have been some questions about desoldering. I have found that for most jobs, I prefer a good quality solder sucker. I'm a big fan of Edsyn Soldapullts. They come in a bunch of styles and sizes (some meant for single hand operation), which I'm sure are great, but I haven't tried them. I've just stuck with the classic model since I first used it. The model number is DS017 or DS017LS for a low static version (I'd recommend this as it doesn't add much to the cost, and I'd prefer the safety of it). There is also an even lower static version, the AS196, but I can't imagine that being worth its cost unless you are working with insanely sensitive components. Solder wicks can also work very well, as others here have said. On the fancy side of things, you can buy desoldering irons with built-in vacuumes, but these are expensive, can be prone to clogs, and just don't make sense for the majority of people. No matter what you use to desolder, make sure you have enough solder to heat up the joint you're trying desolder. If you don't add a tiny bit of solder. You can't desolder that which you can't heat. Even with professional irons, I often still add a tiny bit of solder to a joint I want to desolder to help heat it up.
Finally, a bit of tip care advice. First off, having both a sponge and a brass Brillo pad can be useful (though just one will do). I recommend using a wet sponge for a very dirty tip, and a Brillo pad for quick cleaning throughout the soldering job. A sponge will clean more, but it causes a thermal shock to the tip, and removes all solder, leading to faster oxidization. A Brillo pad won't cause the thermal shock, and will leave a bit of solder on the tip, slowing oxidization. They also make electric tip cleaners, which are really nice, but again, overkill outside of a production environment. Note: DO NOT use a dry sponge for cleaning a tip. It is abrasive and not good for it. If you really want to be picky about oxidization, you can use distilled water, but I'm never that picky myself. If your tip is very dirty or oxidized, Hakko FS-100 and Plato AB-3 are great and cheap products for tip maintenance.
Some final tips for preventing oxidization: Don't leave your iron on when you're not using it for long periods of time. Professional irons will often drop the temperature when they are in a stand because they only take a few seconds to come up to temperature, but this isn't a feature you'll generally find on consumer irons. Also, the hotter your iron, the faster it will oxidize, so if you find that a certain temperature is easy to work with, then increasing the heat might actually be a disadvantage. Lastly, when you are done using your iron, you should put a small amount of solder on the tip to help prevent oxidization.
My personal irons are a Metcal MX-5210 and a JBC CD-1BE. Both of these are high-power professional irons, I have used them on all sorts of sensitive components. I usually solder at around the standard 700°. It is very rare that I bother changing temperature. In fact, with the Metcal, I actually have to buy different temperature tips if I want to change temperature as that iron heats up by self-regulating RF powered tips, and that's more money that I want to spend. Most of the time I've change the temperature on the JBC has been because I've actually wanted more heat to heat up a large piece of metal faster. Both of these irons have power meters on them, so I can see how much power they need to supply to keep up with my work. Most of the time, the initial heat from idle to operating temperature will jump to near 100% power for a second or two (room temperature to 700° is less than 5 seconds), and then stay at around 10%. If I'm using a large tip and having a lot of heat transferred out of my iron (soldering a heatsink or something), that number will go up, but I rarely see it hold much higher than 30%. This shows that having all of that extra power is not harmful, but useful in case I ever need it. Perhaps someday I'll get bored and have enough money to buy a massive tip just to see how much power I can use
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While these irons are nice, they are obviously an overkill for most, and way more expensive than what most people can/will spend. I got them both off Craigslist for excellent prices, so the used market can be you friend here. Good irons can take a beating, just like just about any well-made tool. Here are some more affordable irons that will last you and are worth looking for (be aware of stations being sold as only power supplies or hand pieces!):
- Edsyn 951SX (or similar models, such as the 952SX or 971DX). I used one of these at my old job a lot. It's super reliable, built like a tank, powerful (95 watts), temperature controlled, and tips are super cheap. It comes up to 700° in around 10 seconds or so from what I remember. My only complaint was when I did have a heating element fail in on, I could not for the life of me get it out to replace (well, and I suppose the very dated looks if I'm getting really picky). I did eventually upgrade to a Metcal, as very demanding jobs were taking too long, but last I checked, Gameboy's don't have any huge pieces of metal in them . A new one of these will set you back about $120, but you can find them used for much less than that.
- Several model Hakko irons, such as the FX-888D, FX-951, or the older 936. Hakko makes great tools for the money (and I've met some really nice reps from them). Every product of theirs that I've tried, while clearly not quite competing with the best out there, has done a great job of hitting above its price point. You can easily get an FX-888D for under $100.
- Weller professional soldering stations such WES51, WESD51, EC1002, EC2002, WTCPT (no temp control, temp control set by tip) etc. Avoid the consumer line of products. You can get a much better used professional iron for what the not-very-good consumer irons cost new. An easy way to tell what level of tool you're looking at with Weller is the color. Their consumer tools are orange, while their professional tools are usually some shade of blue or green. Again, you should be able to get a good iron for around $100.
- Lastly, on the higher end of the semi-affordable spectrum, the older model Metcals are pretty common on the used market. Some of them can be gotten for around $100. Sometimes you can get a complete MX-500 for around $200, which is an excellent iron and the model that made me a fan of their products. Note: as I said, Metcal irons are RF, with the heating element being part of the tip, so tips are expensive (~$20). The tips self-regulate their own temperature and cannot be controlled. Standard tips are 700°, with 500°, 600°, and 800° also being available.
Anyways, this got really long, so I apologize if this was a bit of a hijack. If this needs to be removed or moved, I understand. I just noticed a lot of questions on soldering, as well as some bad advice, so I wanted to address it and hopefully help you guys realize that with a bit of knowledge and some decent tooling, it's not hard, scary, etc.
TL;DR:
- Soldering is generally not difficult. If you are struggling with it, there is a good chance that the problem is just as much about your tooling than it is your technique (which will obviously be limited by insufficient tooling). As with anything, experience takes time! Don't get discouraged!
- Get yourself a decent iron, appropriately sized/shaped tips for your work, and good quality solder. Remember, you can never have an iron with too much power, as any high-power iron will allow you to control that power. Any iron that is not temperature controlled (even if it doesn't give you much control over that temperature) is NOT worth your money. "Don't get an iron with more than X watts" is advice I commonly see given, and it is just plain wrong. The more power you have, assuming equally efficient designs, the faster your iron can deliver heat to its tip while your work pulls it away.
- Don't be afraid of high heat. Soldering faster for a very short amount of time is much better than needing to hold an iron on a joint for more than a second or so. Professional (lead-free) soldering is usually done at around 700°, unless working with very sensitive components. You don't really see temperatures below 500° in most professional environments.
- You might have an easier time with a different sized or shape tip. I personally use chisel tips for the majority of work. Even in semi-tight spaces, I rarely find myself wanting to use a conical tip.
- High quality solder will also make your life easier. I recommend AIM Glow Core for lead-free and Kester for leaded. The combination of a good iron and solder will make most soldering easy, and you'll find yourself needing to use extra flux far less.
- Even with high quality equipment, don't be afraid to use flux if you need it. Just clean it up with alcohol afterwards.
- There are various effective methods for desoldering. I personally use a solder sucker for most tasks, but solder wicks work well too. I recommend an Edsyn DS017LS Soldapullt solder sucker. Don't be afraid to add a tiny bit solder to something you want to desolder! I know that seems counter-intuitive, but you need to get a joint hot enough to desolder it. This is especially true with using a solder sucker. I usually put a tiny bit of solder on my tip, touch the joint I want to desolder, and release the solder sucker when I see it flowing.
- The used market is your friend for finding a good iron for a good price.
I hope this help some of you with future mods of consoles!