The case for this gadget slides into the back of the ICOM IC-Z1A HT and powers the radio through its usual battery contacts. I reshaped 5/16″ 4-40 brass machine screws into flat-top studs, then soldered 8-mil tin strips to their tops.
Grab a screw in a pin vise, brace it on the bench vise, and file off everything that doesn’t fit:
The result should fit neatly into the flatted recess, with the top flush in the rectangular slot:
Cut an oversized strip of 8-mil tin and solder it to the stud. I tinned both pieces to get nice solder coverage, although the notion of tinning a piece of pure tin with silver-tin solder did give me pause. It’s all in the flux, I suppose.
Anyhow, put the two tinned sides together and hit the combo with a half-second pulse at 100% duty cycle from my resistance soldering gadget. Perfect:
Then snip off whatever doesn’t fit into the slot with an ordinary (albeit shop-only) scissors, making it just slightly shorter than the slot so the end doesn’t snag on anything. File the sides and corners so they’re easy on the fingers, flatten the strip so it fits neatly into the slot, buff it up a bit, and it’s all good.
Takes longer to describe than to do it, at least the second time you do it…