Improve 8586 Solder Station: "Cigar-tube-hack" (tip Holder) and Power Switch


Introduction:

Improve 8586 Solder Station: "Cigar-tube-hack" (tip Holder) and Power Switch

Recently I bought a cool Kaleep 8586 2-in-1 rework soldering station.

It's a nice tool and it's very cheap. But I thought "Hmm... where to store that solder tips and airgun nozzles? And why is there no mains power switch?"

So if you got the same "problem" ... just look at my instruction here.

The mains power switch was the only thing I missed on this solder station. The main transformer is energized all the time as soon as the station is plugged into wall. I, personally think that's energy-waste and don't like to switch only secondary. So I decided that this station needs a mains power switch.

The tip holder is quite a quick & dirty hack but it does it's job. I like to reuse stuff in unusal ways. So feel free to use other parts as I used.


Step 1:

Disassemble

  1. Screw 1. Unscrew backcover here.
  2. Screw 2: Unscrew the backcover here.
  3. Screw 3: Unscrew the backcover here.
  4. Screw 4: Unscrew the backcover here.
  5. Disconnect mains power cord!

To mount the mains power switch, you need to remove the power cord of the solder station.

Next there are 4 screws you need to remove (store them save!).

Next intermediate step is to remove the power cables from the back of the power socket. To do this, you need to remove the shrinking tube off the (here: red) cables. Next you will desolder the cables off the two (faston) terminals.

Remove left solder for better matching accuracy

Step 2:

New Wires & Switch

  1. Power connector terminals
  2. Toggle switch "input"
  3. Switch "output" to the transformer.
  4. you may want to change or improve this ground connection as well.

Needed:

- Exacto knife

- Soldering iron

- a bit of copper wire

- 6 faston crimp receptables with covers or:

- some shrinking tube or insulating tape

Method 1: (better one)

Prepare 2 wires for the switch, remove solder from the red wires, unstrip wires for about 10mm.

Crimp receptacles on each end of any cable and insulate well (6 connectors in total).

Connect wires in correct order between switch and power-connector. Apply the red cables (transformer) to the "output" of the switch.

Test if everything works fine.

CAUTION! HIGH VOLTAGE! BE CAREFUL!

Method 2: (quick'n'dirty)

Solder wires to each terminal of the power connector.

Continue with step 3 (cut a hole).

Solder wires to the toggle switch.

Step 3:

Cut a Hole

  1. Cut a hole in with the Dremel tool into the backcover (dimensions match your switch's dimensions).
  2. Secure the switch with hot glue (like the power connector was).

You need:

- a Dremel tool or any similar tool or:

- an Exacto knife

- screwdriver & backcover screws

maybe you'll need:

- a file

- hot glue gun

Take the dimensions of your switch (mine is 26mm x 22mm).

Use the Dremel tool to cut the hole for the switch.

Mount the switch in the hole. Optional: Secure with hot glue.

Connect all wires.

Test if everything works fine.
CAUTION! HIGH VOLTAGE! BE CAREFUL!

Mount the backcover again (4 screws).

Step 4:

Tip Holder (Cigar-tube-hack)

  1. Mount angle with matching screw on one side of the station.

You'll need:

- an angle

- metal cigar tube (or any other object that may work....)

- a screw matching the existing holes, matching screwdriver

- some cable ties or some wire (to fix this awsome holder in place)

- some metal drills and any kind of drill (cordless, standing, ...)

- a magic marker or any marker

maybe you'll need:

- some tape, hot glue or similar.

At first, I mounted the angle with a matching screw on one side of the solder station.

Then I tested if the dimensions of my cigar tube match to the size of the solder station.

Next intermediate step is to mark 10...12 points on the tube in one line wich are equaly distributed in one line. I have 10 Tips so i marked 12 points (2 extra).

Drill the holes in steps (1st i drilled 2mm, then 6mm, then 8mm). The outer diameter of the tips is about 6,5mm.

Mount the drilled cigar tube (or any other working scrap) to the angle. I used cable ties at first, but finally hard wire.

Step 5:

Finalize It!

  1. Try if the tips match the holes, you may check the clearence to the body to avoid noise.

Last step is to test and check clearence, stability and add some more features:

I used some insulated hard wire to make a holder for the airgun nozzles.

Just wrap it around the angle and bend it to some hook-like shape. Works very well and looks quite okay.

Have fun!




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