Ultra flexible cable bigger than 8 AWG

[Doctorbass]

Hi guys,

We know HK are having great very flexible silicon wires with size up to 8AWG, but once we want the same kind of cable with bigger size, it become a bit more complicate.
I already orderd 250$ of cable that the supplier said it was very flexible but once i received it, i was disapointed to discover that this cable was using kind of rubber and was really not the same flexibility as the HK turnigy cable and was made with alot less strands.

I am looking for a great source of VERY ULTRA flexible cables, just like the Turnigy from HK, but in the size of 1, 2 and 4 AWG
You know these cable that can be compared to a Wet noddle, that have kind of silicone skin and alot... maybe thousands of strands as thin as a human hair...

Any idea for a good supplier ?

Here is few pics of one that i actually have and that i found in a old Argon 15W laser power supply

Doc

 

[bowlofsalad]

Yeah, with the right wording you should be able to find plenty of sources for it. Stranded electrical wire is what you are looking for. The most typical application relates to things like welding, welders, and extension cords, at least in my experience.

I don't know if this is the best price for it. http://www.wesbellwireandcable.com/Welding/Welding1.html But here is an example.

I found it in google's search engine using the phrase, Stranded electrical wire welding awg 1 copper.

http://www.wesbellwireandcable.com/Welding.html

You can buy 'per foot', to get as much as you need rather than a large roll or bulk.

I used to get this stuff at various big box hardware stores. These places also sell great fasteners for them. You either hammer the strands in place, or fill it up with molten solder and put the wire into it, holding it there to cool.

The best way I found to remove the housing was to heat up a thin piece of metal with a blow torch and use it to cut or melt the housing. The heat melted it away real nicely for myself. Getting the housing off other wise was an incredible pain, I had blisters on my hands trying to cut and tear that stuff off. Part of the problem I kept having with using a knife to cut the housing was, I'd end up cutting some of the strands, which isn't ideal of course.

 

[ian.mich]

Maybe use 2x or 3x turnigy 8awg? otherwise i dont know. What is it that makes turnigy wire so good, and why does more strands make it better? i havent been able to get my 10awg turnigy phases remotely warm.

 

[Doctorbass]

What is it that makes turnigy wire so good, and why does more strands make it better? i havent been able to get my 10awg turnigy phases remotely warm.

the Turnigy are inredibly dense wires( less air betwen the Strands) and I personally tested them at high amp.

The gola is not to rate the cable if it melt or not. .. or become hot or not... it's more that it conduct and is flexible or not.

you can pass 150A thru a 10AWG cable as well.. it will become hot.. but that heat is wasted energy so the goal is to have a cable the right size with low loss and ULTRA flexible.

I dont like many parallel cable as cable harness .. it's more clean install to have one cable per connector i think.

Again, these welding cables are not as flexible as the Turnigy. they are made of strand of 30 AWG whil ethe Turnigy are mde of 38 or 40AWG!

I searched with the number wrote on teh cable i have but this complete number is so specific that it is not really easy to find the supplier that have the exact same cable.

I remember that one supplyer with a name like cablotech or cabletech... etc was offering them but i just can't find it now..

Doc

 

[bowlofsalad]

It is said a human hair is as thin as 30awg. As far as the housing material goes, I guess I struggle to imagine it making that much of a difference. Of course, I don't know your application, hah.

Anyway, http://newenglandwire.com/products/power-leads-and-flexible-interconnects/general-purpose Maybe try giving these guys an e-mail and see what they give you for pricing? They look like they may have what you need, who knows what the price is though. Teflon sounds interesting.

The more I think about it, the less likely I think you will be able to find something like this already made. It sounds like something that will need to be custom produced, a very unique product. I definitely was impressed with how flexible the 1awg or thicker stranded wire was.

 

[Doctorbass]

I think i found something interesting here: polarwire.com

They ofer everyuthing about wiring and battery connections and seem to offer these flexible cables..

http://store.polarwire.com/browse.cfm/flexible-building-wire/2,730.html

Doc

 

[speedmd]

I like using welding cable for the heavier gauges when needing flex. Check out the local welding supply house. Most have nice thick rubber coating and come in smaller gauges.

 

[bowlofsalad]

I think i found something interesting here: polarwire.com

They ofer everyuthing about wiring and battery connections and seem to offer these flexible cables..

http://store.polarwire.com/browse.cfm/flexible-building-wire/2,730.html

Doc

This stuff sounds pretty close to identical to any other welding wire. I am not certain on it's housing material, some of it is listed at least, some kind of PVC with 30awg strands.

I don't know if you read the link I sent, http://newenglandwire.com/products/power-leads-and-flexible-interconnects/general-purpose but they mention silicone housing with 44 – 50 AWG strands.

 

[Doctorbass]

I think i found something interesting here: polarwire.com

They ofer everyuthing about wiring and battery connections and seem to offer these flexible cables..

http://store.polarwire.com/browse.cfm/flexible-building-wire/2,730.html

Doc

This stuff sounds pretty close to identical to any other welding wire. I am not certain on it's housing material, some of it is listed at least, some kind of PVC with 30awg strands.

I don't know if you read the link I sent, http://newenglandwire.com/products/power-leads-and-flexible-interconnects/general-purpose but they mention silicone housing with 44 – 50 AWG strands.

yes tH eNew anglend seem really interesting source aswell. I sent them an email with my request.

I also found this supplier with the Super Vu-Tron orange wire( electric transportation standard color)


http://www.maneywire.com

 

[MadRhino]

I have seen some big, very flexible silicon wire yesterday at Electrovox, Longueuil.
Very similar to Turnigy wire, but strands are not tinned.
They had stock of 4 Ga in 3 colours, I don't know if they had any bigger.

 

[ddk]

I have seen some big, very flexible silicon wire yesterday at Electrovox, Longueuil.
Very similar to Turnigy wire, but strands are not tinned.
They had stock of 4 Ga in 3 colours, I don't know if they had any bigger.

it's available up to 0000 gauge.
Sources for smaller amounts would be broadcast supply businesses.

 

[Punx0r]

I imagine you need something intended to carry very high frequency current?

Aside from high flexibility I can see now reason to use very fine strands. With increasingly fine strands at some point the majority of the conductor area will end up being copper oxide...

Just for reference, I measured a head hair the other day at 0.050mm diameter. Slow day at work...

 

[bowlofsalad]

I imagine you need something intended to carry very high frequency current?

Aside from high flexibility I can see now reason to use very fine strands. With increasingly fine strands at some point the majority of the conductor area will end up being copper oxide...

Just for reference, I measured a head hair the other day at 0.050mm diameter. Slow day at work...

That isn't necessarily true. Any electrical connection can be fully insulated in at least a few ways. There are connectors that you can fill with warm liquid solder, then dip the entire connection beyond the edge of the housing into the solder. I am sure there are several options for oils and such to cover the strands with. Even with just oil of some kind, it might last a long long time, but I am sure there are other ways to seal the connection. With the right care, I am sure the connection would well out last the device.

 

[Doctorbass]

I have seen some big, very flexible silicon wire yesterday at Electrovox, Longueuil.
Very similar to Turnigy wire, but strands are not tinned.
They had stock of 4 Ga in 3 colours, I don't know if they had any bigger.

Great find!! Are they now called Master Vox ?

Is it this one?: http://www.master-vox.com/index_en....scan.org/forums/printer-friendly.asp?tid=9060

i'll take a look

Doc

 

[MadRhino]

Yes, Master-vox. I know there are 2 stores near Montreal now, but I don't know about Quebec region.

 

[ions82]

I've used some car audio power wire that was rather fine. I think the stuff I had was 4 awg. Don't remember the particular brand, though. Might be worth looking into as I have a feeling that some of the aforementioned options would be quite costly.

 

[Kingfish]

Last summer I redesigned my main battery bus and used 6-AWG multistranded marine cable from Tinned Marine Wire. It is flexy though not noodlely like the smaller stuff, and made using 30-AWG tinned strands. The swage-method worked out well for making branches. No problems to report.

Good hunting, KF

 

[speedmd]

The tinned strands are good if exposed or your ride gets wet often. If sealed up well, should last quite well without it. Careful with silicone jacket near oils and grease. It is soft to begin with and swells up and becomes useless when in contact with many common lubricants. Marine stuff looks attractive. Looks like a PVC (105c) jacket. You can add protecting tubing in hot / rub areas.

 

[Doctorbass]

I finally bought the Super Vu tron welding cable From the serie CAROL from General Cable

made of 34AWg strands in arrangement of 1650/34

Also have that Great Orange color skin for EV.

About 2.90$ per foot shipped.

Doc

 

[Kingfish]

Marine stuff looks attractive. Looks like a PVC (105c) jacket. You can add protecting tubing in hot / rub areas.

You are correct

I finally bought the Super Vu tron welding cable From the serie CAROL from General Cable

Touché Doc, that looks like a really good deal on a great product; let us know how it goes 8)

Cheers, KF

 

[melodious]

Those curious can find the specs found here.

 

[gensem]

Doc, try to speak with wojtek

I got 6 awg silicone wires from him sometime ago.

 

[DrkAngel]

0ga - 4ga - 8ga Available

50 ft AWG 4 Gauge TOTAL 25' BLACK 25' - $32.24

 

[Lemlux]

I've been satisfied with the 4 Ga wire purchased from this linked Solar Power generation firm that costs only $0.99 per foot. Vendor swears that the strands are copper. Sheath is thick and very soft/supple. Some reviewers suggest that the strands may be closer to 5 Ga than 4 Ga.

My battery is in 4 sections, and I connect the sections with 4Ga wire that is either connected to another Headway battery segment with a ring lugs or else is butt-connected to 8 Ga wire that is soldered into 6mm XT150 bullet connectors

http://www.windynation.com/products/accessories/connectors/4-gauge-stranded-wire

 

[Doctorbass]

Thanks guys for the recommnedantions..

But never forget that most of teh car audio wires and other cheap non industrial "copper" wires are not always made of real copper and also dont respect the true diameter size of copper and often have more plastic insulation...

Believe me I know what i'm talking about!.. i've been in the car audio hobby with up to 30000W sound system projects with thousand of amps current flow and i saw the difference between real great cable and poor cable. These cable dont have any certifications UL or CSA, etc so they can be any specs..

Industrial cable does.

I know they are $$$ but you dont pay fo rthe name, you pay for quality and safety.

The turnigy cable are a good compromize due to the high temp of the insulation. they dont really better conduct, they just can sustain higher current due to the high temp insulation that's it.

But they dont make any size larger than 8 AWG and for sustained burst of 300-400A hey must conduct instead of genrate heat! :wink:

The super Vu tron with 34 AWG strands is the best candicate i found for quality and flexibility and price on ebay

Otherwise, the welding cable are the second choice for moderate flexibility with 30AWG strands. They are the most popular for EV build too.


Doc