Manufacturer/Supplier to the Pyrotechnic Community

Making electric matches with our new E-Match Head w/Pyrogen

The following steps illustrate how I make my electric matches.

#1    Cut twin lead wire to desired length - often you can save and reuse wire from a show - I generally cut my twin lead 3' to 6' long, but any length is fine.  I prefer to use 24 gage wire but 22 gage from finished shows are OK.

On one end bare the ends approximately 1/4" as shown in the picture to the left.

If your wire lengths are long, it may be easier to fold them into a compact unit - to easily handle in the next steps.

#2    The fixture pictured to the right is what I use.  There are five alligator clips - there could be ten or more  - you decide.  What is important is that you use a metal alligator clip.  It not only holds the head but also acts as a heat sink to keep the head cooler.

#3    Insert a match head into each alligator clip jaw as shown on the left.

The jaw should encompass all of the pyrogen leaving approximately 3/8" to solder the twin lead wire.

#4   Slip the bared end of the twin lead wire onto the match head so that it 'sandwichs' the match head.

#5   Place the tip of the soldering iron onto the bare wire/head and immediately apply solder.

It is important to use a hot iron (recommend 25 - 30 watts) - the idea is to get on and get off as quickly as possible.  Clean copper wire or pre-tinned copper wire works best.  Use standard 60/40 rosin core solder - easily obtained at Radio Shack.

DO NOT USE ACID FLUX!

Turn fixture over and solder the back side.

We have made a few thousand electric matches and a couple of matches have gone off during the soldering - nothing really happens except you get startled - the flame is contained within the alligator clip.  Both times this happened was due to dirty copper wire and we left the iron on the head too long trying to get a good solder joint.

#5   Remove the completed electric match from the jaw of the alligator clip.  Strip approximately 1" to 1 1/2" of insulation from the opposite end of the wire.  Test with an ohm-meter or ODA Continuity Tester. 

ODA Electric Matches are comparable to other commercial matches - they are both friction and impact sensitive.  Handle with care and observe all applicable codes and regulations.

Completed electric matches are regulated items and must be stored in a magazine.

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