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Terminating Shielded Wire With Solder Sleeves

Solder Sleeves

    Today's avionics equipment requires shielding of conductors and without the proper termination of these shields, many problems can arise. Audio / intercom and data bus noise can wreak havoc on an otherwise solid system. Here is a shield terminating technique, courtesy of  D. Harris, using a solder sleeve P/N M83519/1-3 for a twisted pair shielded conductor with a teflon casing that is commonly used to ground the shield of the conductor.

For more information on solder sleeves, Tyco Electronics provides an excellent catalog in PDF format available for download: Solder Sleeve catalog

The proper tools are gathered.
  1. Makita heat gun
  2. Wire strippers 26-16awg
  3. Snap On flush cut dikes
  4. Razor blade
In most cases you will need to measure out about 3 inches of the twisted pair casing.
Using a razor blade, carefully cut around the casing taking care not to damage the braided shield, which is immediately below the casing.
Cut along the twisted pair casing to the end.
Remove the casing from the twisted pair.
Slide the braided shield toward the casing.
Cut the braided shield leaving approximately 1/4 inch of shield exposed.
You should now have approximately 3 inches of twisted pair wires along with 1/4 inch of shield exposed.
With the remaining shield wire exposed, fold it back over the casing. Acquire a piece of ground wire (length and size should be whatever you need for your situation. This example uses 22awg/black) and strip off 1/4 inch of casing.
Position the ground wire and solder sleeve ferrule over the braided shield.
With a heat gun, heat the solder sleeve until the solder flows evenly throughout. Take care not to overheat the connection. Practice will make perfect.
The end result is a properly terminated twisted pair shield!

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