foil wire

[neevel]

Potentially very nice idea with the caps (in my case, I've saved up enough cups and contacts from old rewire jobs that it's probably not useful to me personally). The one issue I could see is: how well to the caps fit with the barrel? If they don't fit snugly, they could be twisted around as the tip and spring get turned, which could eventually lead to the wire or the solder joint breaking in the cup.

As for cleaning out the hole in re-used contacts if the wire doesn't pull out cleanly, Don's already mentioned using a heated surgical probe. Another thing that works is to use the same 1/32" Dremel engraving bit that can be used to drill out smashed German foil screws to drill out the old wire and solder from the contact. For solder, I use 25-gauge flux core solder (the sort commonly used for SMT work)-- if you can't find any at a local Radio Shack or electronics shop, you can easily order a 1 lb roll from Digi-Key for about $15 that'll last you a very long time if you're only doing armory work with it.

-Dave

[Greg Z.]

I've used them for French barrels mostly, but I have also used them on a few German barrels(I am assuming they were German barrels if the points were German).

Concerning the fit, the plastic cups are actually VERY snug but can be pushed down into place without too much problem.

Thanks for the tip about reusing the old contacts, now I have an excuse for buying a Dremmel tool.

Greg Z.

[mifencer]

I did some searching around on the net. I found a company that sells spools of wrapping wire. The price is extremely competitive. You can buy a spool of 500' for $9.46 or a spool of 1,000' for $16.72. There are 8 different colors (sorry no purple).

Here's the website: www.squires.com and here's a link to the wires: www.squires.com/kynar.htm

They only take Paypal for credit cards or talk with them and maybe you can arrange something.

I just ordered a spool and I'll keep you all posted.

[Greg Z.]

I checked out the wire web site. They'll even cut and strip the wire to length. Do they get you on the shipping and handling?
I may try them when my supply of wire runs out.
Greg Z.

[mifencer]

Ok, I received my wire from Squires Electronics. The total cost for 1,000 ft of 30 gauge wire is $20.72. I'm quite satisfied. Here's their number is you're interested: 503-357-7132.

I think next time I'm going to order the 28 guage for a thicker wire. But the 30 gauge is the same size as the Radio Shack wrapping wire.

The pre-cut stuff goes up to 12 inches. I'm not too sure how much it would be if they pre-cut 4 ft lengths (the length of the blade).

Good luck. I'm very satisfied with the whole order.

[Greg Z.]

Warning Warning
I referr you back to my post of 9/28(worlds longest post) decribing my copper disc foil wire method. I have had very poor results with the wire breaking at the copper disc. I believe that it was being cut by the disc. I have STOPPED using them and now recommend the spooling method with solder or reuse the contacts from old wires.
It was fun but it is much faster and so far longer lasting to solder the spooled end of the wire.
Greg Z.