10 Gauge wire thinner than OEM Xlyte wire

[NeilP]

Just been searching around and came across this stuff:


MIL-W-22759/18 wire - extruded thin-wall ETFE insulation

Spec

I measured the OEM wire as O/D...as 3.5...possibly 3.8mm O/D...cant read my writing...but either way, this stuff is the same O/D or slightly less...for 10 Gauge..The OEM is probably 10 gauge any way right?

I know Aircraft Spruce sell the MIL-W-22759/16 wire...this stuff MIL-W-22759/18 has a slightly thinner outer insulation.

Have ordered 12 foot of white MIL-W-22759/16 to see what it is like.

Any one else used this?

 

[icecube57]

OEM is no where near 10G. Atleaset in the older ones. It was more lik 13g,

You also want to look at PTFE instead of ETFE

 

[NeilP]

OEM is no where near 10G. Atleaset in the older ones. It was more lik 13g,

You also want to look at PTFE instead of ETFE

Too late...already ordered the stuff in the link..but why?, I can still leave the old wire in place if necessary.



Just back from the workshop with vernier and a sample of the original wire and a sample piece of the MIL Spec wire in 12 gauge

12 gauge MIL SPEC
max O/D 0.1140 INCH 2.90mm
min O/D 0.1100 inch 2.80mm

Conductor 0.086 (2.18mm)
with exactly agrees with the table of the mil spec wire here




original wire
49 strand conductor:

Conductor diameter:
0.1060 inch 2.69mm

Strand diameter
Max 0.0150 inch 0.38mm
Min 0.0125 inch 0.31mm

Overall Diameter
max O/D 0.1360 3.46mm
min O/D 0.1305 3.30mm

Insulator Thickness
0.0250 inch 0.64mm

So according to these tables:
http://www.rbeelectronics.com/wtable.htm
http://www.powerstream.com/Wire_Size.htm

The original is 10 gauge

 

[icecube57]

The early original clytes had smaller wire vs the new ones out now i guess.

Etfe is ok its a well rounded material. I was looking at the max temp specs on the etfe and it only goes up to 150C when PTFE degrades between 260 to 321C. We normally use PTFE or silicone because we run motors hard and dont want the insulation to melt and short the phase wires. They have a high insulation melting tip. Standard 10G normally coated in PVC at the local automotive store is only good to 80-100C.

Silicone is soft and is not mechanically tough but it can withstand temps to 260C
PTFE is normally hard and and is mechanically tough and it can go up to 321C.
PVC starts to get really soft an pliable at 80C but it melts between 100c-260c depending on its composition.
ETFE is like in the middle of the road between PVC and SILICONE. Its tough it pretty good high temp quality.

The original wire is ptfe. You basically downgraded insulation but upgraded the conduit.

http://en.wikipedia.org/wiki/PTFE

http://en.wikipedia.org/wiki/ETFE

http://en.wikipedia.org/wiki/PVC

 

[NeilP]

OK,

I had seen the 150ËšC, and was not even thinking about standard automative PVC wire. I have seen that melt before..
I had thought that 150 was going to be OK.

What sort of temps can I be expecting in the motor ...I know, lot of variables...how hard driving, power, rider weight, hill gradient etc etc, but what would 'normal' temps be considered...and what would 'getting too hot' be?

 

[bigmoose]

icecube can you share US vendors for bulk silicon insulated wire?

 

[NeilP]

Here is the original wire, pictured next to a cut off of 12 gauge Mil Spec 22759/12 wire

The original is 49 strand about 3.5mm diameter...as spec'd further above