Anybody have any Ideas on how to keep wires from twisting inside the hilts?

[samurai_rob]

I've tried pre-twisting in the other direction and shortning them up, but I'm still having trouble. The LED leads popped off my US board and I'm gonna have to re-solder them. Any Ideas out there to combat the scourge that is twisting wires?

[Sairon]

heat shrink.

[samurai_rob]

I've used heat shrink over my wire joints, but the parts of the wires not covered still twist like crazy! I've Already had wire twists cause shorts in one of my LEDs. Do you guys heat shrink the entire remaining wire, or just the joints? Also, my high stress point seems to be the leads on my boards. After a few battery replacements, they pop off and have to be re-soldered. I don't want you guys to think I'm wreaking havoc with my sabers, It's just that I've been having to dissassemble them a lot lately.

[Sairon]

try rechargeable batteries, and for the wires try making a sled with a beam down the middle that you can tape the wires to, so they don't move.

[eastern57]

What exactly are you screwing? Is it the pommel? Or is it a center section? We need details to give you specific answers.

But generally speaking: for center section, simply holding the internal parts in place with needle nose pliers or hemostats works well; for pommels, either devise a counter spin option or counter-twist the wires. 26g wire or smaller makes this MUCH easier.

[FenderBender]

Ive never had problems with wires twisting. The way I put everything together, there is no twisting of the wires......hmmm. Need more info we do.

[Jay-gon Jinn]

You sholdn't have to worry about wires twisting if you were using MHS parts....they are designed to eliminate that in most cases....I agree with eastern and Fenderbender, more info is needed before we can really give you some tips on what to do about it.

[samurai_rob]

I'm at work right now, but will post details later. Thanks, guys.

[Novastar]

You sholdn't have to worry about wires twisting if you were using MHS parts....they are designed to eliminate that in most cases....Really Jay Gon? Myself, I find that in many cases, if your wiring is tight--screw together parts really make it tough to prevent wires from twisting.

This isn't a dig on MHS parts... after all--they are modular, custom made and very cool. However... I've noticed that the best way to prevent wire twisting is to have almost NO parts screw together--other than the pommel. And I'd assume that many folks might even avoid THAT (a screw-on pommel)... and just use a bolt or screw to mount, etc.

Anyhow... yup, it can be a science so-to-speak to avoid twisting wires in certain cases.

[Spaznick]

Funny you should ask, I just came up with a solution for the exact same issue! Check my thread on it:

http://forums.thecustomsabershop.com/showthread.php?t=6947

(if your issue is regarding twisting wires as a result of speaker being mounted in the pommel):)

P.S., I suppose in theory you could adopt similar changes to all the threaded parts of the saber so they are essentially "wireless", though it would be a huge pain in the ass.

[xwingband]

Good planning?

Add extra wire to account for the twist. OR on most cases I make a sled to hold the parts minimizing the parts that could even twist.

[Jay-gon Jinn]

Really Jay Gon? Myself, I find that in many cases, if your wiring is tight--screw together parts really make it tough to prevent wires from twisting.

This isn't a dig on MHS parts... after all--they are modular, custom made and very cool. However... I've noticed that the best way to prevent wire twisting is to have almost NO parts screw together--other than the pommel. And I'd assume that many folks might even avoid THAT (a screw-on pommel)... and just use a bolt or screw to mount, etc.

Anyhow... yup, it can be a science so-to-speak to avoid twisting wires in certain cases.

You'll notice I said in "most cases".....I have had problems with it myself, when installing a recharge port or switch in the MPS inserts...I found away around it, though. you have to make a "sled" or "chassis" to hold all of your electronics so the MHS parts just screw together over it.

I had this issue when installing the rechargeport in BS-2 when I put the CF 2.63 in it. It went something like this:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Brass%20Saber%202%20CF%20Mods/84d74d52.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Brass%20Saber%202%20CF%20Mods/e1c31350.jpg
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Brass%20Saber%202%20CF%20Mods/c8745938.jpg
Yeah, it aint purty, but it works! See the cut pvc pieces? Those can be sqeezed together so they'll fit inside the pommel. When the pommel is screwed together with the hilt, it clamps them together against pvc sled inside the saber, pushing the MPS insert out towards the pommel. Because the force of the compressed pvc pieces isn't that much against the i.d. of the pommel, I can screw the pommel in place with out twisting the wires off the recharge port. This is still a work in progress....I plan to make a more accurate length spacer for theMPS insert someday when i get time.

In all of the other MHS/sinktube combo sabers I've built, I've never had an issue with wires twisting off.

That being said, I have to echo X-wingband on this, too....you shouldn't throw together a saber without planning out out first.

[Novastar]

I remember that gorgeous setup of yours Jay-Gon! And hey, the looks on the inside don't matter! (Come to think of it... if we're talking comparisons to the fastest YT-1300 in the galaxy... uh... looks don't count on the OUTSIDE either... but she's got it where it counts: CF!!)

Ditto on the "never twisted wires off" thing... but yeah, you certainly need to be on your toes and PLAN first if you wish to avoid it.

But ask Corbin someday about the "padawan saber mishap" that he wired up for BOP I... which was in an MHS setup. It had to do with twisted wires at the pommel (with a recharge port similar to yours Jay-Gon)... crossed + and - from batteries (!!!!)... umm... a cardboard box... and... uhhhh... ummm...

...well, a little bit of smoke... and... errrrr... Fire. :confused: :o :cool:

[Jay-gon Jinn]

This wasn't the only saber of mine that has had problems with twisting wires! See the one in my signiture? That one is notorious for twisting wires, and that is the main reason it still sports an MR Anakin soundboard, and not an Ultrasound or CF.....

[Spaznick]

Here's some pics of my work around

http://i545.photobucket.com/albums/hh395/spaznick/saber%20sound/DSC02938.jpg
http://i545.photobucket.com/albums/hh395/spaznick/saber%20sound/DSC02939.jpg?t=1230806219
http://i545.photobucket.com/albums/hh395/spaznick/saber%20sound/DSC02940.jpg?t=1230806257
http://i545.photobucket.com/albums/hh395/spaznick/saber%20sound/DSC02941.jpg?t=1230806277
http://i545.photobucket.com/albums/hh395/spaznick/saber%20sound/DSC02942.jpg?t=1230806290

[Spaznick]

http://i545.photobucket.com/albums/hh395/spaznick/saber%20sound/DSC02943.jpg?t=1230806311
http://i545.photobucket.com/albums/hh395/spaznick/saber%20sound/DSC02944.jpg?t=1230806339

[kyncaid]

Could you pre-twist the wires in the oposite direction first then when you screw it together you will be untwisting them?

[Novastar]

Yup.


.

[samurai_rob]

Sorry I've been away so long, but I fixed my US board tonight and found the reason why my wires were twisting so bad. It is the way my hilt goes together in relation to the switch that was putting the extra stress on the board connections. If I'm very careful on how I assemble the hilt, everything seems to be ok. Got some pics I' posting of the final finished hilt (all that's lacking is a d-ring in the pommel) over in the gallery, If anybody wants to see it. Now, onward to # 2! :D