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High Voltage (HV) Lead Splicing

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The following procedure was written by Curt Palme. 

While I’ve been critiqued for this, there are times where you need to splice a high voltage (HV) lead due to an arc or to the fact that the HV lead end is different. Now, before we start, the best way to change an HV lead is to cut off the entire HV lead and rubber anode cap right at the bell of the tube and replace the whole lead, but if you’re short on time and don’t have a new lead handy, this is the way to get arc-free HV lead splices.

You need to get some heat shrink tubing, the stuff that shrinks about 40-50% when heated. You need a heat gun, although a lighter will work as well.

Start by stripping back the HV insulation, and form as small a connection as you can. Put a minimum of 5 layers of two or three different sizes of heat shrink over the HV leads, two or three pieces of heat shrink over each HV lead. Make sure that each layer of heat shrink is slightly longer than the next, and allow for at least 1” of overlap onto the original insulation area (see image below):

Solder the splice point so that stress can’t pull the lead apart (see image below):

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