Terry Hewitt has been an automotive electrician for more than 38 years. After becoming frustrated with how complicated or unreliable the various soldering irons and guns he had used were, he set out to invent his own. He wanted an iron that would heat up almost instantly – his goal was 5 seconds from when he pressed the power button.

The early prototypes were all battery–powered. This eliminated the need for power leads that could pose a tripping hazard or, worse, pull the soldering iron out of its holder or off the bench. Battery power meant that there was no flame. This allows the iron to work outside in the wind without any degradation in performance. Battery power also means that the cost of the iron is the final cost – there is no need to purchase additional fuel.

The original units worked the way he wanted, but still didn’t heat up fast enough to meet Terry’s 5-second goal. This is where his friend Brett Hoy joined the project. Brett has been a motor mechanic for more than 35 years and was also somewhat of an inventor. The two men put their heads together to tackle each challenge as it unfolded.

With the goal of 5 seconds in mind, they switched the power source to lithium-ion battery packs. These battery packs store a great deal more energy per cubic inch and provide more voltage over the discharge curve when compared to nickel cadmium and nickel metal hydride. They also do not exhibit a memory behavior that is common with other rechargeable battery types. The switch to lithium ion allows the iron to melt solder within 4 seconds and be ready to make a connection in 5 seconds. The three lithium ion cells enable the iron to be used for weeks without needing to be recharged.

After weeks of real-world use, another challenge arose. The original switch design had a protruding actuator. On occasion, the iron would turn itself on if it rolled onto the switch. Terry and Brett sourced a suitable replacement, and now the iron is safe to use. They also added a warning buzzer to alert the user that the iron is on.

After using their irons for many years, and having worked out all the bugs, Terry and Brett responded to peer pressure and realized that people all over the world would enjoy using their soldering iron as much as they do. The number of applications is nearly endless, and the performance continues to be impressive.

It was at this point that Aussie Irons was born. Their soldering irons are available in many cool powder-coated colors and will soon be offered in two different sizes.

Click here to purchase your Aussie Iron and start saving time now!

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