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Multi-Conductor Cable: Cotton-Covered, Waxed and Twisted
A cable of several insulated wires in one bundle, such as the four leads of a strain-gauge bridge. Each copper wire is wrapped in cotton thread and soaked in beeswax, then the wires are twisted together and covered again.
Beginner
An afternoon
Instructions
1
1
Cut the conductors
Cut the conductors
Cut one copper wire per conductor (four for a bridge), a little longer than the cable.
Materials for this step:
Copper Wire4 lengthTools needed:
Wire Strippers2
2
Wrap each wire in cotton
Wrap each wire in cotton
Clamp one end in the vise and the other in the hand drill's chuck, keeping it taut. Wind cotton thread on in a close spiral with no gaps, then a second layer the opposite way.
Materials for this step:
Cotton Thread1 as requiredTools needed:
Bench Vise
Hand Drill
Scissors3
3
Soak in beeswax
Soak in beeswax
Melt beeswax in a double boiler and draw each covered wire slowly through it. Wipe off the excess and let it set.
Materials for this step:
Beeswax1 as requiredTools needed:
Double Boiler
Hot Plate4
4
Twist them together
Twist them together
Lay the covered wires side by side, clamp one end and twist them together evenly with the drill.
Tools needed:
Bench ViseHand Drill5
5
Cover the bundle
Cover the bundle
Wind an outer layer of cotton over the twisted bundle and wax it again.
Materials for this step:
Cotton Thread1 as requiredBeeswax1 as requiredTools needed:
Bench ViseDouble BoilerHot Plate6
6
Test it
Test it
Strip the ends. With a multimeter check each wire end to end, and check that no two wires touch.
Tools needed:
Wire Strippers
Multimeter7
7
Limits
Limits
Cotton insulation is only good for low temperatures, up to about 105 °C (Wikipedia, Magnet wire), and for dry places and low voltages such as instrument leads. The method is general workshop practice, ours.
Materials
3- 4 lengthPlaceholder
- 2 as requiredPlaceholder
- 2 as requiredPlaceholder
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CC0 Public Domain
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