- 1). Cut the ends of the copper tubing you plan to join. Using a small, disk-type pipe cutter, fit the cutter to the pipe ends, tighten the disk and rotate the cutter around the tube's circumference until you have cut it completely. Take care to cut the tubing evenly.
- 2). Ream the inside of each pipe. Using the reaming blade on the pipe cutter, carefully remove any burrs from the inside of both tubes. Do not overly force the reamer, as it might deform the tube end.
- 3). Clean both pipe ends with an abrasive pad. Rubbing the pipe ends removes any burrs left from the cutting process and contaminates. Removes any difficult burrs found on the tube ends with a wire brush.
- 4). Scrub the copper fitting cups, which you will slide over the ends of copper tubing to join the pipes. Scrub the fitting cup inside and out with an abrasive pad, removing any contaminants. Wipe the fitting cup and both pipe ends with a clean rag.
- 5). Apply soldering flux to both tube ends and the fitting cup. Flux improves the welding process, making the solder hold better. Carefully apply a thin layer, using the brush included with the flux. According to the American Welding Society, "Use a soldering flux that will dissolve and remove traces of oxide from the cleaned surfaces to be joined, protect the cleaned surfaces from reoxidation during heating, and promote wetting of the surfaces by the solder metal."
- 6). Insert both tube ends into the fitting cup, twisting both tubes to distribute the flux evenly. Remove any excess flux with a rag. Don safety goggles and work gloves at this time.
- 7). Light the torch using a torch lighter. Open the torch fuel valve, and squeeze the torch lighter, causing a spark that lights the torch. Heat the tubing and fitting cup by holding the torch a few inches away from and perpendicular to the tubing, sweeping the torch back and forth over the entire assembly.
- 8). Apply the solder once the tubing heats up. Keeping the torch flame underneath the center of the fitting, place a length of solder extending from the roll off center to the bottom of one end of the fitting cup. Once it begins to melt, insert the solder directly into the joint. Continue soldering in this fashion around the joint circumference until solder begins to drip from the joint. Dripping solder means the joint is full of solder. Using this same procedure, solder the other fitting cup joint.
- 9). Let the copper tubing cool naturally. Do not touch the tubing while cooling, and do not splash water to cool it. Splashing water may stress and crack the copper tubing.
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