ARRGHH Trying to rewire

[LTranter]

Okay.. some of you will get giggles out of this, some of you may chastise me, but here it goes!
I have tried TWICE now to rewire a blade my son and I affectionately call 'Grandpa' since it is one his first 2 electric blades. The other met a dastardly death via breakage.
I had one our club armorers teach me how to rewire, took meticulous notes, in addition to downloading Craig's info on rewiring here. My first attempt was with a premade wire, and I after testing and testing, found a bare spot of wire just past the barrel. My second attempt was from scratch, and once again, I am noticing "thin" parts in the insulation. I noticed when handling it that it doesn't take much to fray it, so are there any hints??

L

[SJCFU#2]

My first attempt was with a premade wire, and I after testing and testing, found a bare spot of wire just past the barrel. My second attempt was from scratch, and once again, I am noticing "thin" parts in the insulation. I noticed when handling it that it doesn't take much to fray it, so are there any hints??

First off, make sure that you only feed a couple of inches of wire through the barrel at first, then only pull the rest of the wire through after tightening the barrel (most rewiring guides I've seen say to do it this way however
I have seen a couple that advocate pulling the wire all the way through before screwing the barrel onto the blade).

Take a good look at the blade. If the edges of the groove are sharp than that may be what is causing the problem. A few minutes with a needle file should be enough to knock down any sharp edges.

You might also try applying a small (very small) amount of nail polish to the wire immediately below the plastic cup before wiring. That should help to provide a little bit more insulation at what appears to be a problem area.

You might also consider getting a wire made by Gary Sprull (I think that HOM Fencing (aka Purple Fencer) may sell them). They are probably as close to indestructible as any wire out there.

Finally, if all else fails, seek professional help (most armorers are quite willing to assist, especially if you appear willing to learn).

[fencerbill]

Second not pulling all the wire through before tightening the barrel.

Also, Put about an inch of wire through the barrel, then start the barrel onto the end of the blade. A lot easier than putting the barrel on, then trying to poke 2 Epee wires through.

When the barrel is tight, then pull the wire(s) through. Make sure you keep a mild slow pull on the wire.

As you push the cup down into the barrel, make sure you keep that slight pull on the wire. If it bunchs up inside the barrel, it is more likely to short to the barrel.

If you really have trouble with nicking the wire near the tip, put about half an inch of heat shrink on. Most people use a hot air blower/hair dryer to tighten the heat shrink. I like to use a candle, keep the heat shrink above the flame and keep moving it. You can really control the shrink that way. You can put the heat shrink around a Foil wire or around both Epee wires. Probably not enough room for separate heat shrink around each Epee wire.

Take a really good look at the threaded end of the blade. Some blades have a very shallow groove at the end, which forces the wire against the barrel, enhancing the possibility of scratching through the insulation.

I like to touch up the end of the blade, if necessary, so that the wire(s) exit near the center of the end of the blade. I usually use a Dremel with thin cut off blade like it is a grinding wheel to do this. Or you can use a needle file.

Are you using the appropriate prayers to the God of your choice? That sometimes helps. Or do you know a Voodoo expert?

Good luck.

[Purple Fencer]

You might also try applying a small (very small) amount of nail polish to the wire immediately below the plastic cup before wiring. That should help to provide a little bit more insulation at what appears to be a problem area.

Now THAT'S an idea I hadn't thought of before! Need to write that one down.

I agree with everything else said here.

You might also consider getting a wire made by Gary Sprull (I think that HOM Fencing (aka Purple Fencer) may sell them). They are probably as close to indestructible as any wire out there.

That would be me!!

Actually, they're not any more tough than a normal German wire...but the design elements AREuperior to any other wire I've seen.

Keep in mind that they're designed for German foil barrels, not French (the diameter's slightly different)

[LTranter]

Thanks for the tips, guys! I almost have enough courage mustered up to try again!

L