Splicing headwires

[Terry Plata]

This is a splicing method I use for tight spaces like inside the motor housing or anywhere a big, fat wire splice will just not work. 

1. Strip and clean about 1/2 inch of both wires

2. Slide a short piece of shrink tube on the new wire

3. Pull a 2 inch single strand of copper wire from a donor wire, tie a loose overhand knot and put it over the new wire.

4. Push the stranded wires together so they somewhat intertwine and temporarily clip them together. I use an alligator clip for this but if you were around in 1969 we called is by another name.

5. Move your knotted loop to the center of the splice and tighten. Tweezers work well here.

6. Tightly wrap the donor wire strand in one direction, then the other end.

7. A drop if solder is optional but will make the splice bullet proof.

8. Move the shrink tube up and heat to insulate and strengthen.

9. To finish the head wires, I use a flat woven shoelace as a fabric conduit. Cut off the plastic end tips and you have a nice woven tube to dress up your head wires. 

Terry Plata

 

 

 

Edited September 26 by Terry Plata
Duplicate photo

[Terry Plata]

IMPORTANT!! There is a glitch affecting this posting. Jamie Horner has been working to solve but no resolution so far. I am receiving notifications that there have been responses or questions about the head-wire splicing but HAVE NO VISIBILITY. I cannot see or read any of these. PLEASE don't think I am ignoring you. For specific questions perhaps try PM, email at TERRYPLATA@HOTMAIL.COM.

Thanks to everyone for the feedback,

TP, Terry Plata

[David Kilnapp]

I very much like this approach - very elegant. I'll be using it in the future. Thanks Terry!

[Jim Roadt]

wish I read this before I globbed up my GE smoker fan. Very helpful...for next one

[Trevor Andersen]

I like this method and I also use the Western Union splice short tie. I have used the long tie where I needed to change headwire direction and bend it at an angle to exit the housing. I try to use a dab of solder at the ends of the wire on each side just to minimize chances of it unwrapping.

https://en.wikipedia.org/wiki/Western_Union_splice

[Terry Plata]

Trevor, Thanks for sharing the Western Union splice. I like that, especially for solid conductors. The key is a strong union while keeping a slim splice. 

[Jared DelOrfano]

Thanks for sharing this! Do you also typically tie a knot/or put a zip tie on the headwire before it comes out of the motor housing? I’m planning on tying knots for the wiring in the base for my AOU restoration but wasn’t sure if that’s a typical step for the motor housing as well.

[Terry Plata]

Jared, If there is room in the motor housing a zip tie would be a good idea. Usually it's a challenge just to get things buttoned up upon reassembly and the head wire doesn't see a lot of stress. On the other hand I use an underwriters knot for the power cord. Lots more room in that AOU base. I have an AO that is my daily driver and an AOU waiting for restoration. Great fans!

 

[Steve H Jordan]

That is very comprhensive and extremely useful, thank you

I will go and try it !