What diameter solder wire do people use? I was using a bent, pointy
metcal iron with an 0.5mm ish tip, and 0.5mm solder wire. (Some lead,
tin and copper alloy). I found that the solder balls up on the end of
the wire to the point where it can dwarf an 0402's contact pad.
I use metcal's 0.020 conical tip (about 0.5mm) and 0.020 solder.
Lately, I've been using solder paste - a dab on the pads, position the
part, use the iron to reflow it. Less hands needed, and the part
doesn't move around as much.