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Old 07-31-2009, 06:55 PM #1
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Question Connecting a ground wire to an aluminum case

I have a question for the builders out there. My current build will need to have the negative of the laser driver connected to the inside of the barrel of the host. The host is aluminum so I know soldering will be out of the question (even though it is possible for those who know how and have the proper equipment). So what is the best alternative to connecting wire to aluminum?


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Old 07-31-2009, 07:47 PM #2
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Default Re: Connecting a ground wire to an aluminum case

Press it against the wall via a screw, or squeeze it in between heatsink and wall, or something like that.
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Old 07-31-2009, 07:49 PM #3
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Default Re: Connecting a ground wire to an aluminum case

Most flashlight manufacturers wedge the neg wire down the side of the PCB, it works but is not ideal.
If I have somewhere that I can put a washer I make one out of brass wire, drill a hole through the ali case and solder the wire to the washer which is clamped tight by when you assemble the body.

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Old 08-02-2009, 06:28 PM #4
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Default Re: Connecting a ground wire to an aluminum case

You can also try to solder it, with one of these kits that time by time appears on ebay, like as example these ones

ALUMINUM SOFT SOLDER & FLUX KIT - eBay (item 390062524908 end time Aug-27-09 08:59:14 PDT)

ALUMINUM SOLDERING KIT *Solder & Flux "HARRIS-BRAND" - eBay (item 390035111046 end time Aug-31-09 05:09:12 PDT)

ALUMINUM SOFT SOLDER & FLUX KIT w/Metal Tip Applicator - eBay (item 390018789755 end time Aug-18-09 07:23:11 PDT)

but, considerate that solder aluminium at low temp, sometimes, can be a frustrating experience (also cause it draw so much heat from the soldering point that you need a very efficent soldering iron )
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