Rats. All was good when I took this photo, but the joint broke loose when I pushed the cap farther on. Using flux on the wires did make soldering easier.
I have a little roll of silver solder from another project. Couldn't hurt to try that. I've been told it makes strong joints.
A spring-loaded needle contact seems like it should work, but I'm not sure I have the tools (or the eyesight) to engineer it.
It just occurred to me that I could cut away a section of the cap to expose that joint. After everything else is in place and soldered, I could sneak the tip of the soldering iron through the gap to make the last connection at the stub. That would avoid stressing the joint when I slide on the cap. If the electrical contact is sound, I could reinforce the joint with a dab of epoxy and then glue the cap section back on.
That's all for now. Goin' on a road trip with my sons until the weekend.
Phil Nelson
