Wiring Considerations

[merlin1]

Hello all, good afternoon. I am working on a BUSH AC11 and a civilian wartime set. I am clear about what type of wire to use for component wiring, but what would you recommend for replacing the wiring to the loudspeaker on both these models? Any tips greatly appreciated. Thanks Chris

[kalee20]

Silicone rubber insulated stuff.

Looks the job - More flexible than PVC - Doesn't shrink back with soldering iron heat - Easy to work with.

I'd like to think it's what manufacturers would have used if it had been available in their time. So, not really cheating!

[elanman99]

+1 for ease of working. I use several gauges and colours of silicone insulated wire for lots of the internal wiring of thing I make. Its expensive compared with standard PVC connecting up wire but has many advantages. The type I use has scores of extremely fine wires (0.07mm) so is extremely flexible and even when frequently flexed withstands frequent handling without breaking any strands at solder tags etc.

Mostly only available in about five colours but I found an Aliexpress seller with about 10 colours in a wide range of gauges.

I can see that it could look 'period' too.

Ianb

[merlin1]

Thanks both. Very helpful. Cheers Chris

[Silicon]

Modern insulated wire looks wrong and it is partly due to the shiny surface.

Black PVC can be made to look more like rubber by rubbing it with, or pulling it through a scratchy scourer.

[Paul JD]

If you want a more vintage correct look cloth covered push back wire is available from many guitar amp component suppliers. I get mine from here http://www.hotroxuk.com/amp-parts-se...re-8181-0.html

[elanman99]

Originally Posted by Silicon

Modern insulated wire looks wrong and it is partly due to the shiny surface.

Black PVC can be made to look more like rubber by rubbing it with, or pulling it through a scratchy scourer.

Silicone insulated wire is not shiny.

Whilst the colours might be more colourful than those seen in an old wireless the wiring in that might have just faded over the years.

Ian

[David G4EBT]

For some years now I've used silicone rubber flex which forum member Phil Marrison, 'SWB 18' can supply in about ten muted vintage colours, in two gauges, which are very much in keeping. It's heatproof and strips really easily. Phil doesn't often post on the forum, but he's on the forum browsing most days so will answer a PM.

Hope that helps.

[HamishBoxer]

Met up at the BVWS in Harpenden in March,a perfect gent I add.

[David G4EBT]

Originally Posted by HamishBoxer

Met up at the BVWS in Harpenden in March,a perfect gent I add.

Indeed.

Phil invariably has a stand at the NVCF, where I stock up each year.

[PaulR]

Is single core wire available in a reasonably thich gauge? I find the flexible multicore flex rather difficult to get through the holes in solder tags without leaving some of the individual wires behind.

[Al (astral highway)]

Originally Posted by PaulR

Is single core wire available in a reasonably thich gauge?

Hey Paul, yes, single strand copper wire is available way thicker than you'll need it for this job! The thicker gauges (than you'll need) obviously have a limit to their flexibility, but this won't be an issue if you choose a gauge that's going to fit inside the eye of a lug in a tag-board.

If it's a short run like this, you can always put a single-strand copper wire through a separate sleeving, which you'd ideally heat-shrink for looks. It's a bit more expensive if you don't have the heat-shrink but it answers your question.

[Neil Purling]

Is there a substitue for 'Systoflex' one could use to disguise non-vintage wiring? Especially if the wiring is carrying a high voltage. I am not sure if the silicone rubber wire is rated for 250V.

[Herald1360]

You can get silicone rubber tubing to slip over tinned copper wire.

0.6mm thick silicone rubber is good for 500V.

Originally Posted by PaulR

Is single core wire available in a reasonably thich gauge? I find the flexible multicore flex rather difficult to get through the holes in solder tags without leaving some of the individual wires behind.

If you twist the strands tightly and tin the extreme end, you can push the stranded core through easily enough then bend it over as you would(?) with solid core anyway.

[M0FYA Andy]

Something I haven't been able to source is single-strand wire with silicone rubber insulation. I asked Phil a while ago, he did some research and drew a blank.
So if anyone knows a source...…………….
Yes, it can be created with tinned-copper wire plus silicone rubber sleeving, but the sleeving can't be a tight fit on the wire so not quite the same.

[elanman99]

Originally Posted by Neil Purling

Is there a substitue for 'Systoflex' one could use to disguise non-vintage wiring? Especially if the wiring is carrying a high voltage. I am not sure if the silicone rubber wire is rated for 250V.

The silicone cable I use is rated at 300/500V (test is at 2KV) so its insulation properties should not be a problem, I'm not sure its good at high frequencies, or at least I have never seen it used in VHF circuitry.

Ian

[ex seismic]

Herald1360 mentioned about bending the wire over after going through a tag, as used to be done. I find this a major annoyance when trying to remove wires and I'm sure I read somewhere that during or after the war a study was done that found there was no improvement in reliability with bent over wires compared with wires just poked through the tags. Can anyone confirm this impression of mine?

[elanman99]

Originally Posted by M0FYA Andy

Something I haven't been able to source is single-strand wire with silicone rubber insulation. I asked Phil a while ago, he did some research and drew a blank.
So if anyone knows a source...…………….
Yes, it can be created with tinned-copper wire plus silicone rubber sleeving, but the sleeving can't be a tight fit on the wire so not quite the same.

I did once see solid cored silicone wire and I think it was in some commercial catering equipment, I doubt very much whether its something that anyone carries in stock as its probably only made to order.

Last time I tried to source some 2x0.5mm CSA silicone flex it was a 10,000m minimum order. 2x0.4mm is available but its a bit marginal current wise for my application.

Ian

[machineage]

A Google for 'SID Solid Core Silicone' turns up a few results from suppliers in the UK.

Available in sizes from 0.20mm up, rated at 3/500V working & 1500-2000V test.

Are these of any use?

http://www.klaceycables.co.uk/defaul...0WIRE-aory.pdf

http://centralcables.co.uk/wp-conten...one-cable1.pdf

[Herald1360]

Originally Posted by elanman99

Last time I tried to source some 2x0.5mm CSA silicone flex it was a 10,000m minimum order. 2x0.4mm is available but its a bit marginal current wise for my application.

Was that even at the higher current rating that it would have had compared with PVC insulated wire? Or was it a voltage drop problem (thinking 12V maybe)?