Thanks racer1812. I knew I shouldn't sand the tip, but thought I'd try as I couldn't get the tip clean using the method provided in the Hakko instructions. Still trying to figure out the heating issue. I have emailed and called Hakko and have not heard back from them yet. I tried to contact them via their live help online, but can't seem to get that website feature to work. My LHS is out of tips right now, but I'll pick one up when they get them back in stock and start over. I'm a little disappointed in Hakko for not contacting me back yet...been a week.

One other question. How long should a tip last, and what would cause one to degrade?...type of solder?, temp setting?, how long you leave it on?, etc.

How long? depends on all of the above. For me if I'm not using it, it's not on. Unless you hard wire your batts. (pre lipo days) I don't see a reason to have it on if you're not using it. And at the track if it's not on people don't want to borrow it!!

Biggest reason for ruining a tip is applying to much pressure. The tip isn't vice grips to hold something down with a lot of pressure. Light pressure is all that is needed, just maintain contact so that it transfers the heat to the solder and connections.

I've had my iron for 4 years now, and pre-lipo days it would spend the entire day turned on. I have 3 tips and the 2mm tip is the one that is usually on the iron. It still works as good as the day I bought it.

Thanks for the..uh..tip Tubaboy. You'll be happy to know that there are no flattened out wire ends on any of my stuff! I used to use a basic 40 watt pencil iron pre lipo days. Used to keep it burning all day long on race days and never had a problem. It's been a while since I've done much soldering. I bought the Hakko because of it's good reputation and it being a station and all. I wasn't planning on having this be a regular item at the track with me.

After cleaning the tip and spending some time re-tinning it, it is working fine now. I'm still a little concerned about the heat though...not sure it's heating up to full temp.