DIY battery powered soldering iron

When it’s time to get started on a project and put our irons in the fire, we usually reach for a nice Weller or Hakko soldering iron. Unfortunately, that isn’t possible when we’re soldering something away from a wall outlet. Portable soldering irons usually range from slightly to completely terrible, and [Adam] thought he could do better. He put together an Instructable for a portable battery-powered soldering iron that’s extremely easy to build.

[Adam]’s project mounts a standard Radio Shack soldering iron tip in an E-10 flashlight bulb socket. Power is provided by 6 Volts of AA batteries, with a small switch added for the obvious safety concerns. Although [Adam] could have added a small project box, he chose to build his entire project around a piece of wood. This is an excellent choice in our humble opinion; wood doesn’t melt, has very low thermal conductivity, and anyone using this iron should be smart enough to turn it off if the handle starts smoking.

While this isn’t the best possible portable soldering iron (we’re partial to the disposable-lighter-fueled torches with a soldering iron attachment), it’s much better than the ColdHeat soldering iron that received consistently bad reviews.

Edit: [Adam] updated his build to be a little safer after this story was posted. We changed the original title pic to reflect this; here’s the old one.

Hackaday Links: September 15, 2011

Open-source Mars rover

[Seth King] wasn’t satisfied with current robotics platforms that don’t work well outdoors. He started the Open Rover Kickstarter with the end goal of having a 6-wheel robot with a rocker-bogie suspension just like the Mars landers. We’re sure it’ll be an interesting platform.

Adding a Flash to a key fob video camera

[doctormord] picked up a key fob “spycam” and was surprised that there wasn’t any onboard illumination. Then again, that would probably defeat the purpose of the “spycam.” A transistor, LED and resistor later (translation), he had a camera with a light. Pics here.

Automated WEP cracking

This is a video of [Elliott] using his autocrack script to crack a WEP wi-fi network. It took [Elliott] less than a minute to crack a network he set up. Lesson: don’t use WEP.

Adding wi-fi to a laptop the fast way

This laptop used to have a broken Mini-PCIe wi-fi adapter. [Mikko] fixed the wireless by taking out the old card and hooking up a USB wi-fi adapter. He soldered the USB leads directly to the back of an internal USB port and used hot glue “to prevent bad things from happening.” A very easy, fast, and cheap way of fixing a broken wireless adapter.

Han Solo’s soldering iron

When [Craig] was 15, he broke the Bakelite casing of his father’s soldering iron. Being a good son, he fixed it by gutting his original Star Wars Han Solo blaster. Nice, but not as great as Starsong from My Little Pony.

DIY vaporizer

Here’s a DIY vaporizer build. It uses a 30 watt Radio Shack soldering iron as a heat source that is regulated with a common dimmer switch. This is done by removing the soldering tip and replacing it with threaded rod attached to a brass pipe fitting assembly. This is housed inside of a Mason jar with a copper pipe for air intake and another for output. Not surprisingly the creator tipped us off anonymously, saying that this a “smoking accessory”. A bit of searching and we came across this Wikipedia article about a Volcano Vaporizer which sheds light on what one is used for.

We don’t condone using illicit substances. But even more so, we’re skeptical about breathing through this thing because of the warning that [Anon] included about noxious vapors put off by the epoxy putty when it heats up. Still, it’s an interesting build so we though we’d share.

Solder station hack adds temperature control

Take that cheap fire stick you call a soldering iron and turn it into a real tool. [Giorgos Lazaridis] turned his 30 watt soldering iron into a temperature controlled soldering station by adding a thermistor just above the tip to monitor how hot things are getting. A MAX6675 takes care of the thermocouple and shoots a digital temperature value off to the PIC 16F88 which controls the unit by taking user input from a potentiometer and displaying the settings on an HD44780 character display. His use of a dissected ‘wall wort’ inside of the ATX power supply carcass used as the case for the station is a clever hack. See it melt some metal in the clip after the break.

This makes a nice upgrade to our solder station guide, which had a temperature controlled iron but lacked the sensor and automation seen here. Continue reading “Solder station hack adds temperature control”

Tools: Aoyue 968 3-in-1 soldering and rework station

The $10 “fire-starter” is the most common beginner soldering iron. These are simple irons with a hot end, a handle, and little else. There’s no temperature control or indication. Despite their simplicity, they’ll do just about anything. You can solder any legged chip type with this type of iron. We used fire-starters in the lab for years.

Eventually, we wanted a hot air rework tool to salvage SMD parts and solder QFN chips. Aoyue is a relatively unknown Chinese brand that makes soldering stations very similar in appearance and function to Hakko. Aoyue stations are recommended and used by Sparkfun Electronics, something that factored heavily in our decision to buy an Aoyue. Read more about our experiences with this tool after the break.

Continue reading “Tools: Aoyue 968 3-in-1 soldering and rework station”

How-To: The Hacker’s Soldering Station


A good soldering station and fume extractor is a must for anyone interested in hacking and modding, but not everyone can afford the expensive professional models on the market. This How-To and the tips within it will guide you through the process of building an inexpensive homebrew fume hood complete with built-in time and temperature controlled soldering station and all the soldering tools you need.

Continue reading “How-To: The Hacker’s Soldering Station”