One of the most frequent questions I receive is concerning the deterioration
of the white silicon or vinyl cords on the older Weller TCP series soldering
irons.

Weller does sell part number TC217, which is a black replacement cord with 3
pin plug already installed.
This is a good solution for the irons that have the Lightweight Nylon handle
with black heater insulator/plug-in (after 1977) and mate to the WTCPN and
later stations.

However, this is an expensive solution for the earlier TCP irons that had a
phenolic handle/finger heat shield, such as the WTCPK (military set with
4-pin Jones plug) or W-TCP and WTCPL stations.

For these units, you have to cut off the 3-pin plug (expensive part of the
assembly) from the replacement cord to wire the Jones plug or directly wire
to the TCP base unit.

The phenolic handle irons used a metal ground strap that also serves as the
cord's clamp and strain relief.
Removal and replacement of the old cord from this metal ground strap is
difficult (and can be dangerous without proper tools)

Some restorers have used silicon or fiberglass/silicon sleeving or silicon
tubing to build a new cord by removing the old vinyl or broken silicon
insulation.

Another option is to use a replacement silicon cord from Rapid electronics
(UK), order code 85-0590
which sells for 3.88 British pounds - considerably cheaper. This cable is
not appropriate for the lightweight nylon handle, since it is slightly
larger in outside diameter and uses the next high wire gauge 20 AWG ..
instead of the original 22 AWG used by Weller.

Rapid order code 85-0590 Silicone, heat-resistant cable for soldering
irons.
a.. Especially recommended for use with mains powered irons.
b.. Ideal for educational applications.
c.. Survives contact with a heated soldering iron tip.
d.. Convert existing PVC cabled irons to safer silicone cable.
e.. Pre-stripped and tinned.
f.. Overall length 1.5 metres.
g.. Suitable for use with all irons using 3-cored flexible cable.

g. beat
====
"g. beat " @spam protected wrote in message
...
I have been slowly scanning my collection of Weller Tech Sheets and posting
these on BAMA.
Some of these instruction, parts and repair sheets go back to Weller
Electric in the mid 1960s --
and are no longer available from CooperTools / Weller.

http://bama.edebris.com/manuals/weller/

w9gb