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flexible wire

Discussion in 'Electronic Repair' started by James Sweet, Jun 9, 2008.

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  1. James Sweet

    James Sweet Guest

    Anyone who has ever owned a Volvo 240 wagon will know that there's one
    really annoying design flaw in an otherwise nearly bulletproof car. All
    the wiring for the rear wiper, power lock, defogger, center brake light
    and license plate lights passes through the hinges so that it gets bent
    90 degrees each time the tailgate is opened resulting in a need to
    replace the tailgate wiring harnesses about once every 5 years. I've
    seen some people wire around the hinges but that just looks tacky to me.
    I'm curious if there's any modern super flexible wire out there that can
    hold up to this repeated flexing? 18 AWG is fine, none of them carry a
    particularly high current. There's room for a bundle about the diameter
    of a pencil through each hinge. Ideas?
  2. N_Cook

    N_Cook Guest

    Twist up, in a drill, 6 strands or so of long lengths of 30-35AWG/35-40SWG
    or so gauge and cut into 3. Plait up those 3 lengths and then cut in 3 and
    plait together the 3 lengths of that intermediate. Keeping the "flat" side
    in the same sense which will be the sense through which the hinge action
    takes place.
  3. **Multi-Contact make a VERY tough, very flexible, 512 strand, silicon
    sheathed wire which will last the distance. Farnell carry it. You may need
    to buy quite a bit though.
  4. neon


    Oct 21, 2006
    there is nothing wrong with the wire so why replace it? there is tapes that you can wrap around the point to protect the wire from strain. not electrical tape . this tape can be streched 1:5 and when done it will become a solid piece of rubber. if it get braised repeat on that spot. next time buy a LEXUS engineered properly
  5. James Sweet

    James Sweet Guest

    Hmm, interesting, ok, I should specify though, anything I can get in the
    US? Farnell may be willing to ship over here, but there's gotta be
    something local.
  6. James Sweet

    James Sweet Guest

    Could probably be done, but I'm sure it would require some fabrication
    and bodywork, it'd be easier to just replace the wiring harnesses every
    few years.

    I'll look into test lead wire, might hold up ok.
  7. JeffM

    JeffM Guest

    Imagine a steel whire that is constantly flexed at one point.
    Now imagine the same wire whose flex point is made into a helix.
    The stress is spread out and fatigue is greatly reduced.
    This sort of thing is done all the time on glass doors / burglar
    and by musicians (guitarists' coily cords).

    Use RTV to have the coily part retain its form.
    Use multi-filar windings as required.
    No need to even change the existing color code.
  8. **Here in Australia, we use this thing called 'Google'.

    It is brilliant. You can find pretty much anything you want. Anyway, type in
    'farnell us' into the little box. From that you get a link to:
  9. James Sweet

    James Sweet Guest

    Thanks smartass.

    I figured I'd search for the product when I get home, unless someone
    knew of a particularly good place to get it. I get sick of these snide
    "google it" replies, if you don't have a helpful answer, don't reply at
    all. Half the time Google is useless from all the stupid sites that hook
    searches and lead to unrelated crap, particularly if you don't know the
    general name of what you're looking for, and for many things that varies
    by region.
  10. Eeyore

    Eeyore Guest

    This is just a tailgate problem ?

    Use silicone insulated wire like used in test leads but make sure you
    protect it well with an overall sleeve.

  11. Eeyore

    Eeyore Guest

    Silicone if I may be so bold.

    It's excellent stuff.

    Don't forget additional PVC sheathing.

  12. Eeyore

    Eeyore Guest

    Just learn to refine the 'search terms' and all that crap will go away. It just
    needs a bit of intelligence, that's all.

    For example did you know you can use a minus term in the search ? Such as -fuckwit

  13. Eeyore

    Eeyore Guest

    His email addy says 'trashmail', so I guess he lives in a trash can ?

  14. James Sweet

    James Sweet Guest

    If you bothered to check out, you'd find that it's an
    email forwarding service. After my previous email account become so
    flooded with spam that it was nearly unusable, I set up a number of
    disposable forwarding accounts to my new one. If I start getting a bunch
    of spam on one, I can kill it and switch to another while still
    maintaining the same private email account.

    Unlike some, this is not completely anonymous, nor is it munged in any
    way. Send an email to the trashmail address and it will land in my inbox.
  15. James Sweet

    James Sweet Guest

    Yes I'm well aware of how to use Google, I've been using it since it
    first appeared on the scene. I only asked because I thought someone
    might happen to think "hey I know just the thing, I bought some
    from...." and save the searching and guesswork, failing that, I'll find
    it myself. Apparently people would rather make snide remarks rather than
    being helpful of keeping quiet.

    Either way, I found what I needed, to the rest of you, forget I even asked.
  16. Just get a GMail account. I use it without munging all the time. I get
    thousands of spam messages piling up in my spam folder, but I can't
    remember the last time that a spam message reached by inbox.

    Nicholas Sherlock
  17. Eeyore

    Eeyore Guest

    So why do you behave like such a shit ? A Hotmail addy works for me.

  18. Eeyore

    Eeyore Guest

    Yes they did and they ALL said SILICONE insulated wire.

    Problem ?

  19. Eeyore

    Eeyore Guest

    Actually not in my experience from good knowledge of those who say simply that
    in exasperation.

    The trouble is that so many people aren't capable of thinking logically (or
    'otside the box') that they miss the search terms that get the result they're
    looking for. Imagination is the key.

    Longest it's taken me with a tricky search, 5 minutes approx.

  20. bz

    bz Guest


    More and more often, usenet users block all postings from gmail accounts
    and google groups postings because of all the spam and trolling that comes
    from that direction.

    bz 73 de N5BZ k

    please pardon my infinite ignorance, the set-of-things-I-do-not-know is an
    infinite set.

    remove ch100-5 to avoid spam trap
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