Solder is plenty strong to do that job. It sounds to me like the solder isn't bonding properly, either to the connector or the top plate. Since it has failed a second time, just re-flowing it probably isn't the answer. I'd suck up the existing solder, get put some flux on the stuff, and re-solder it.
Solder itself is pretty strong, but when it is the only bonding agent between two flat surfaces at a 90 degree angle, it looses much of its ability to be strong.
Solder when used as "glue" as it is in this instance, does not respond to physical shock force very well. Epoxy would absorb more of the stress and force then solder, solder instead of absorbing that energy, will simply pop off.
Yes, stripping it down all the way, and totally re doing it is what it needs (well it really needs a better design), and that was what I was worried of the first time I went about just re-flowing it, and that is somethign I will probably let Protovapor fix.
I am not feeling particulary excited about stripping it completely, as I feel it would need to have the wires removed from the 510 in order to get the outside of it hot enough to have that large of a blob of solder both removed, and re-applied.
I am fairly certain PV puts that massive glob of solder on the outside of the 510 BEFORE they solder the wires and install the center pin / grommet, otherwise they would almost certainly melt.
Could I do this all myself, sure, but this would be the third fix I have done myself, I want protovapor involved before I end up re building the whole thing myself.
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