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Building custom twisted servo extentions

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Old 01-11-2006, 10:45 PM
  #1
lraflyboy
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Default Building custom twisted servo extentions

Greetings,
I was happy to read the article in Model Airplane News (March, 2006) about making your own servo leads. I know now that I am not nuts, trying to do this myself. Having experienced a little of this project, myself, I have a few questions. First, I wonder about the type of wire to select. As directed in the article, I purchased the wire from RadioShack. I purchase three roles in black, read and green, all in one package. The wire I purchased was solid 22 gauge wire, not braided. RadioShack did not have braided wire. I built one cable with this wire, and thought that the wire crimping may be in question. I thought that maybe I should be using braided
wire, as the crimping will be more secure. So, I went to Fry's electronics to buy some braided 22 gauge wire. Inspection of this braided wire from Fry's electronics, I found two things I didn't like. One: The insulation is meager (thin), and two, the braided wire is not copper, or tinned copper. So, I thought to not bother to use it, and ask for help.
As I am working on my first gasser, I am working to insure that I don't experience electro magnetic interference. There is so much information posted in the engines forum about how to avoid RF problems. So, I thought I would start with this step of building twisted servo leads.
So, what is best? Braided or solid wire for building your own cables?

Thank you in advance.
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Old 01-11-2006, 10:56 PM
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Default RE: Building custom twisted servo extentions

You can't use solid, or single conductor, wire where vibration is an issue as it will work harden and break. If you investigate servo wire it is not braided but multiple twisted strands. This is the type to use. I make most of my own extensions and with a little patience and the right crimper you can produce a servo or battery lead just as good as the factory. I buy most of my supplies from FMA Direct, wire, plugs, pins, etc..
I hope this helps.
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Old 01-11-2006, 11:12 PM
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Default RE: Building custom twisted servo extentions

I have had very good luck using wire (.26 ga, single conducter 7/30 strand) purchased from Mouser.com. 100 foot roll for about $7.00. I use the AMP Mate-n-lock connectors, along with the associated crimp pins (bought the crimper at radio shack for about $15). I like the AMP connectors since they are not proprietary. I simply cut the existing servo leads, then put in the new connectors. I can make an extension as long as I need it. Never had one fail on me yet.

Brad
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Old 01-12-2006, 06:33 AM
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Default RE: Building custom twisted servo extentions

Making your own extensions is fun and easy. However, as others have said, you can't use solid wire where it will be subject to vibration. What you want is 22 gauge stranded wire. It can be copper or not, either will work well. Other than that, go for it. Definitely use the proper crimping pliers rather than try to mash the connector with pliers. Yea, I know, but I've seen guys do it.

Dr.1
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Old 01-12-2006, 11:38 AM
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Default RE: Building custom twisted servo extentions

Thanks for the help.
I was really suspicious of the one cable I built with the solid (one strand) wire. I could see that it would break in vibration or even my own frequent handling.
I've finally found the proper wire supply at RadioShack. They have 22 gauge standed wire in three spools of 75' for only $5.99. This is good copper wire with good insulation. The wire girth, at any rate, matches the best production servo wires that I have seen in 22 gauge. This will sure save on cable billing (after I get over my learning curve).
Here is a RadioShack link the the wire of choice:
http://www.radioshack.com/product/in...entPage=family
for item #227-1224.
Thanks for all your help.
Larry
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Old 01-13-2006, 04:46 PM
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Default RE: Building custom twisted servo extentions

please keep in mind that that cheap 7 strand wire is only a hair better than solid wire. i wouldn't use anything less than 19 strand where vibration is an issue.




dave
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Old 01-13-2006, 04:50 PM
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Default RE: Building custom twisted servo extentions

Good point Dave, the more strands, the stronger the wire. The best wire I've found for hd applications is 22ga with 150 strands of 44ga available from FMA Direct.

We, are Devo.
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Old 01-15-2006, 04:27 AM
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Default RE: Building custom twisted servo extentions

Look at this
http://www.airwildpilotshop.com/More...product&id=568
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Old 01-15-2006, 04:55 AM
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Default RE: Building custom twisted servo extentions

You can get wire plugs sockets crimptools everything you need at very good pried from
http://www.ashtekelectronics.com/ He even has wire with a clear insulated negative strand so that you can check easily for corrosion.
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Old 01-16-2006, 02:16 AM
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Default RE: Building custom twisted servo extentions

Having attempted to build a few wires now, I can tell you that I am disappointed with the crimper as supplied by Maxx Products. This crimper, I find will not do a complete crimp in one pass. The crimping surface does not cover both the crimp sleeve for the wire and the sleeve that will crimp over the wire insulation. It is clear to see that the tool is not wide enough. I've had several results, depending on the initial orientation of the crimper. Either the wire doesn't get crimped entirely, or the insulation doesn't get crimped properly. I had one situation where the sleave for the insulation oozed out of the crimper. I believe that I will invest in one of the crimpers as offered by Ashtek Electronics. This item looks to be a solution for acurate and safe crimping.
Asktek Electronics seems to be a great resource.
Larry
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Old 01-16-2006, 07:30 AM
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Default RE: Building custom twisted servo extentions

Most of the crimpers of this type require two seperated crimps in different sized crimp jaws. The wire is crimped first in one jaw and the insulation is crimped in another. I two have been dissapointed in the crimpers out there including the model from Radio Shack but I finally found one that works extremely well from an electrictronic supply house.
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Old 01-19-2006, 10:16 AM
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Default RE: Building custom twisted servo extentions

Air Wild has very nice twisted wire and twisted wire extensions at good prices.
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Old 01-19-2006, 11:04 AM
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Default RE: Building custom twisted servo extentions

What is ashtech like to work with being in the UK.. how long do deliverys take and how much does the shipping run? I am very interested in their products, good price, the crimper looks very nice too.

Regards,
Randy
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Old 01-19-2006, 04:43 PM
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Default RE: Building custom twisted servo extentions

I have ordered product from Ashteh, like this:
==============================
Date Ordered: Tuesday 17 January, 2006

Products
------------------------------------------------------
1 x 10M Heavy Duty Twisted Servo Cable (JR) (AE-SCA-014) = $10.31
2 x ASHLOK 3-Way Connector Kit (AE-AKS-001) = $14.72
1 x Servo Crimp Tool (AE-TMC-003) = $29.49
------------------------------------------------------
Sub-Total: $54.54
UK Royal Mail Rates (Shipping to US : 0.62 kg(s)): $21.79
Total: $76.33
Total to be charged in GBP: £44.03
====================================

This copy show information from a email received from "Mr A Jones".
My experience on the internet ordering: I was unable to process a credit card,
as the system kept upchucking with a problem for some reason. I made several
emails to express my concern for the billing problem, but got no reply.
So, I opted for a paypal purchase. This went without a hitch.
I have been getting email notification of the order status, and the copy above
was included in a "dispatch" message.
As you can see the shipping isn't cheap. I hope "Royal" is a good work in UK.
As it takes being a mail order junky to build nice custom airplanes in this
hobby, I suck it up and pay freight.
Delivery is pending. I am looking forward to trying the crimper. I think many
products found overseas may be better. Like medicines being suppressed by
the FDA, there must also be a FHPA..
Larry


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Old 01-19-2006, 05:48 PM
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Default RE: Building custom twisted servo extentions

Thanks, I will have to make sure I place a larger order to justify that much shipping. Some one mentioned that they got a good crimper from a US electronic supplier.. any one know what brand they were? The crimpers I bought work, but I the crimps are not the greatest sometimes.

Best regards,
Randy
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Old 01-19-2006, 06:13 PM
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Default RE: Building custom twisted servo extentions

Randy, I'll try and get that info for you, I'm in the middle of a move right now so it might take a couple of days.
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Old 01-26-2006, 05:33 PM
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Default RE: Building custom twisted servo extentions

Randy.
I received my shipment from the U.K. today. That's 9 days for
Royal mail.
This is my discovery.
The crimper is superior to that supplied by our favorite hobby vendors.
I haven't tried it yet, however.
Here are the stats:
Manufacturer: "H Tools" (r)
Product part number: "HT-225D"
Availability in the United States:
http://www.jameco.com/webapp/wcs/sto...oductId=338677

Jameco is in Belmont, California.
Check out the "View Catalog" and "View Technical Documents" pages from
the link above. Jameco evidently has many/much similar product as Asktek.
Larry
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Old 01-26-2006, 06:55 PM
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Default RE: Building custom twisted servo extentions

One of our fellow RCU members has a small online store I've been ordering from . Evan Chapkis stocks all the materials for making your own servo extentions and wiring. I got the gold pins , crimper and 10-feet of 22 guage Servo Wire.

Check him out.
[link=http://www.rcaccessory.com]RC Accessory.com[/link]
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Old 01-26-2006, 11:32 PM
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Default RE: Building custom twisted servo extentions

How about skipping all the headaches related to the connectors and just solder in the extra length you're looking for? I buy Hitec heavy duty 20 ga wire from Servo City, $15 for a 50' roll. I pretwist it before I cut it, so I know how much length to cut without being too long or coming up short. I suspect a soldered joint has less resistance than connectors as well, and definitely no worries about connectors corroding.
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Old 01-27-2006, 12:17 AM
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Default RE: Building custom twisted servo extentions

Crimping the fine wire we use is iffy.
Too little pressure, erratic servo operation.
Too much pressure great operation till the 3 strands left break.
We are not working House wires.
Soldering is visually checkable and can be wrapped past the stiff solder wire point and any melted plastic.
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Old 01-19-2008, 06:50 PM
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Default RE: Building custom twisted servo extentions

I use [link=http://www.cheapyharnesses.com]www.cheapyharnesses.com[/link] They carry great quality wire (twisted & flat) 22 & 24 AWG . They have servo connectors and many other things and shipping is cheap and only takes a few days! Best prices I found
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