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Secrets Techniques

 
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jloram



Joined: 07 Nov 2009
Posts: 54
Location: United States

PostPosted: Thu Apr 19, 2012 8:13 pm    Post subject: Secrets Techniques Reply with quote

Sixty years I've been doing this! Built all my own ham radio gear as a teenager in the 50's, got a EE degree from a prestigious university, spent my adult life as a development engineer designing medical and laboratory instruments. You'd think I could strip a multiconductor shield Tefzel insulated cable in my sleep, but it's a bit(at)h ([email]bit(at)h[/email])! I make a mess of the shield when I try to remove the Tefzel. What is the secret trick to it!

thanks all, -john-
[quote][b]


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MNellis



Joined: 16 Aug 2008
Posts: 15
Location: Georgetown, TSX

PostPosted: Thu Apr 19, 2012 8:37 pm    Post subject: Secrets Techniques Reply with quote

You've been doing it so long, you've probably wore the tool out or at the very least, dulled it.

Mike
[quote] Sixty years I've been doing this! Built all my own ham radio gear as a teenager in the 50's, got a EE degree from a prestigious university, spent my adult life as a development engineer designing medical and laboratory instruments. You'd think I could strip a multiconductor shield Tefzel insulated cable in my sleep, but it's a bit(at)h ([email]bit(at)h[/email])! I make a mess of the shield when I try to remove the Tefzel. What is the secret trick to it!

thanks all, -john-
Quote:

[b]


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jloram



Joined: 07 Nov 2009
Posts: 54
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PostPosted: Thu Apr 19, 2012 10:19 pm    Post subject: Secrets Techniques Reply with quote

Tool! A special tool!? I love tools! What tool!

-john-

[quote] From: owner-aeroelectric-list-server(at)matronics.com [mailto:owner-aeroelectric-list-server(at)matronics.com] On Behalf Of Mike Nellis
Sent: Thursday, April 19, 2012 9:36 PM
To: aeroelectric-list(at)matronics.com
Subject: Re: AeroElectric-List: Secrets Techniques

You've been doing it so long, you've probably wore the tool out or at the very least, dulled it.

Mike
Quote:
Sixty years I've been doing this! Built all my own ham radio gear as a teenager in the 50's, got a EE degree from a prestigious university, spent my adult life as a development engineer designing medical and laboratory instruments. You'd think I could strip a multiconductor shield Tefzel insulated cable in my sleep, but it's a bit(at)h ([email]bit(at)h[/email])! I make a mess of the shield when I try to remove the Tefzel. What is the secret trick to it!

thanks all, -john-
Quote:



href="http://www.matronics.com/Navigator?AeroElectric-List">http://www.matronics.com/Navigator?AeroElectric-List
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PostPosted: Fri Apr 20, 2012 4:11 am    Post subject: Secrets Techniques Reply with quote

At 11:12 PM 4/19/2012, you wrote:
Quote:
Sixty years I've been doing this! Built all my own ham radio gear as a teenager in the 50's, got a EE degree from a prestigious university, spent my adult life as a development engineer designing medical and laboratory instruments. You'd think I could strip a multiconductor shield Tefzel insulated cable in my sleep, but it's a bit(at)h ([email]bit(at)h[/email])! I make a mess of the shield when I try to remove the Tefzel. What is the secret trick to it!

The secret is go ahead and 'trash' the shield.

I have a bunch of 22AWG, 3-conductor shielded
that a common Stripmaster more-or-less strips
the outer jacket and probably 80% of the shield
strands. Then I use a solder-sleeve
to put a neat pigtail on the damaged shielding.

There are normally no currents flowing in the
shield. If your grounding pig-tail gets good
electrical connection with only one of of the
strands, you're good to go. More than likely
you can get good connection with 10% or more
of the shield stranding. The neat thing
is that the pigtail under heat shrink covers
the carnage.

I'll see if I can dig some of the stuff up
and do a comic-book series of pictures on the
process tomorrow.



Bob . . . [quote][b]


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PostPosted: Fri Apr 20, 2012 4:14 am    Post subject: Secrets Techniques Reply with quote

At 11:12 PM 4/19/2012, you wrote:

Sixty years I've been doing this! Built all my own ham radio gear as
a teenager in the 50's, got a EE degree from a prestigious
university, spent my adult life as a development engineer designing
medical and laboratory instruments. You'd think I could strip a
multiconductor shield Tefzel insulated cable in my sleep, but it's a
bit(at)h! I make a mess of the shield when I try to remove the Tefzel.
What is the secret trick to it!

The secret is go ahead and 'trash' the shield.

I have a bunch of 22AWG, 3-conductor shielded
that a common Stripmaster more-or-less strips
the outer jacket and probably 80% of the shield
strands. Then I use a solder-sleeve
to put a neat pigtail on the damaged shielding.

There are normally no currents flowing in the
shield. If your grounding pig-tail gets good
electrical connection with only one of of the
strands, you're good to go. More than likely
you can get good connection with 10% or more
of the shield stranding. The neat thing
is that the pigtail under heat shrink covers
the carnage.

I'll see if I can dig some of the stuff up
and do a comic-book series of pictures on the
process.
Bob . . .


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PostPosted: Fri Apr 20, 2012 4:57 am    Post subject: Secrets Techniques Reply with quote

John and others,   A tip I learned from this list was to use a hot soldering iron.  As luck would have it, I had a wood burning knife in my tool kit which worked wonderfully on stripping tefzel wire.  Just run the sharp edge of the hot knife around the wire, melting the tefzel and pull off the end!   A bit of the pain for retrofitting under the panel but when building was a piece of cake as the top panel skin was not yet riveted in place.

Marty RV-6A N826METime: 09:13:30 PM PST USFrom: "John Loram" <johnl(at)loram.org (johnl(at)loram.org)> Subject: Secrets TechniquesSixty years I've been doing this! Built all my own ham radio gear as ateenager in the 50's, got a EE degree from a prestigious university, spent my adult life as a development engineer designing medical and laboratoryinstruments. You'd think I could strip a multiconductor shield Tefzelinsulated cable in my sleep, but it's a bit(at)h! I make a mess of the shield when I try to remove the Tefzel. What is the secret trick to it!thanks all, -john-


[quote][b]


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PostPosted: Fri Apr 20, 2012 6:54 am    Post subject: Secrets Techniques Reply with quote

At 07:53 AM 4/20/2012, you wrote:
Quote:
John and others, A tip I learned from this list was to use a hot soldering iron. As luck would have it, I had a wood burning knife in my tool kit which worked wonderfully on stripping tefzel wire. Just run the sharp edge of the hot knife around the wire, melting the tefzel and pull off the end! A bit of the pain for retrofitting under the panel but when building was a piece of cake as the top panel skin was not yet riveted in place.

The problem with hot strippers and multi-conductor
shielded is that it is insufficient to simply
part the outer jacket at the strip-length.
When the jacket is molded over the braid
which in turn is conformal to the spiral
wires beneath, there is a great 'attachment'
of the jacket with the braid.

So even if you achieve a clean separation of
the strip length of outer jacket, the
unwanted insulation generally refuses to
slide off. Here's a shot of a cleanly separated
length of about 1" on the end of a shielded
trio. No way is that stuff going to slide off.

[img]cid:.0[/img]


Tefzel jackets are also very
thin. PVC insulation is thick enough that
'pushing' a strip-length off at the cut
tends expand the inner diameter of the
insulation lessening the grip on the wire.
Tefzel is so thin that the same push fails
the insulations column strength in compression
and it simply bunches up . . . and rips the shield
strands but still hasn't budged in the space
beyond.

[img]cid:.1[/img]


My favorite process uses the generic Stripmaster
with knife-edge dies . . .

http://tinyurl.com/bol9x2n

In this case, a 22AWG trio is nicely decapitated
with the 14AWG die.

[img]cid:.2[/img]

The dies just barely cut the jacket but does get a
'grip'.

The resultant strip comes out looking like this:

[img]cid:.3[/img]


You wind the shield remnants tightly around the wires like
this . . . keep the diameter small.

[img]cid:.4[/img]

If the wire is 'old' . . . the shield strands may
be less than bright. Optionally, you can prepare the
strands to accept a solder sleeve by 'tinning' them
but shake off all excess solder.

[img]cid:.5[/img]

Then apply solder sleeve for a finished product that
looks like this.

Alternatively, you can go the po' boy's solder sleeve
route with techniques adapted from these pages:

http://tinyurl.com/87lea6o

http://tinyurl.com/dgg2nb

Now, if you've got a steady hand, a sharp knife and
more patience than I, you can do a circle-cut and then
slice the outer jacket down the side for an end result
that can be processed like this:

http://tinyurl.com/7ungs6c

Until I get time to do a real html comic book and
properly index this piece on aeroelectric.com,
I've published a draft pdf at:

http://tinyurl.com/6t56qrn




Bob . . .


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PostPosted: Fri Apr 20, 2012 7:56 am    Post subject: Secrets Techniques Reply with quote

You can use a razor blade against a cutting board to get a good clean cut, then just pull off the insulation by hand.

Another method is to take a sharp pair of wire strippers and use the 'pipe cutter' method -- using a loose grip that still marks the insulation, turn the wire cutter around the cable until you have a clean, deep score. Pull off the insulation by hand as before.

That should leave you with a nearly intact shield with only 5-10 strands severed. As Bob mentioned, you don't need all of it, so I sometimes take half of it and hack it off with flush cutters before twisting the remainder into a wire for termination.

On Apr 19, 2012, at 11:12 PM, John Loram wrote:

Quote:
Sixty years I've been doing this! Built all my own ham radio gear as a
teenager in the 50's, got a EE degree from a prestigious university, spent
my adult life as a development engineer designing medical and laboratory
instruments. You'd think I could strip a multiconductor shield Tefzel
insulated cable in my sleep, but it's a bit(at)h! I make a mess of the shield
when I try to remove the Tefzel. What is the secret trick to it!

thanks all, -john-


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jloram



Joined: 07 Nov 2009
Posts: 54
Location: United States

PostPosted: Sun Apr 29, 2012 3:32 pm    Post subject: Secrets Techniques Reply with quote

Well, that works like a charm!... I've spent so many years trying not to melt the insulation that I was not taking full advantage of the properties of Tefzel. I've encountered solder sleeves in the past, but never appreciate their purpose.

onward and upward (someday), -john-

[quote] From: owner-aeroelectric-list-server(at)matronics.com [mailto:owner-aeroelectric-list-server(at)matronics.com] On Behalf Of Robert L. Nuckolls, III
Sent: Thursday, April 19, 2012 9:39 PM
To: aeroelectric-list(at)matronics.com
Subject: Re: Secrets Techniques

At 11:12 PM 4/19/2012, you wrote:
Quote:
Sixty years I've been doing this! Built all my own ham radio gear as a teenager in the 50's, got a EE degree from a prestigious university, spent my adult life as a development engineer designing medical and laboratory instruments. You'd think I could strip a multiconductor shield Tefzel insulated cable in my sleep, but it's a bit(at)h ([email]bit(at)h[/email])! I make a mess of the shield when I try to remove the Tefzel. What is the secret trick to it!

The secret is go ahead and 'trash' the shield.

I have a bunch of 22AWG, 3-conductor shielded
that a common Stripmaster more-or-less strips
the outer jacket and probably 80% of the shield
strands. Then I use a solder-sleeve
to put a neat pigtail on the damaged shielding.

There are normally no currents flowing in the
shield. If your grounding pig-tail gets good
electrical connection with only one of of the
strands, you're good to go. More than likely
you can get good connection with 10% or more
of the shield stranding. The neat thing
is that the pigtail under heat shrink covers
the carnage.

I'll see if I can dig some of the stuff up
and do a comic-book series of pictures on the
process tomorrow.



Bob . . .
Quote:


href="http://www.matronics.com/Navigator?AeroElectric-List">http://www.matronics.com/Navigator?AeroElectric-List
href="http://forums.matronics.com">http://forums.matronics.com
href="http://www.matronics.com/contribution">http://www.matronics.com/c
[b]


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PostPosted: Mon Apr 30, 2012 4:07 am    Post subject: Secrets Techniques Reply with quote

At 06:30 PM 4/29/2012, you wrote:
Quote:
Well, that works like a charm!... I've spent so many years trying not to melt the insulation that I was not taking full advantage of the properties of Tefzel. I've encountered solder sleeves in the past, but never appreciate their purpose.

Yeah, they're kinda cool. I'm seeing some po' boy's solder
sleeves showing up from suppliers on the net at attractive
prices. I'm going to acquire some as see how well they
work.

I'm a bit surprised to find them offered to the commercial
installation crowd. PVC or even the higher temperature PVC
insulations are king. Not sure you can put a legacy RayChem
solder sleeve on this wire. But these new kids on the block
just might feature lower temperature solders (yes my children,
there ARE other alloys that will do that melty-glue-thing) along
with some lower temperature shrink and sealants. We'll have
to see.

In any case, I'm pleased that your dragons are at least
"behind bars" if not completely dispatched . . .


Bob . . . [quote][b]


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jloram



Joined: 07 Nov 2009
Posts: 54
Location: United States

PostPosted: Fri May 04, 2012 10:27 pm    Post subject: Secrets Techniques Reply with quote

I knew there must be a tool for this!!!

http://www.aircraftspruce.com/catalog/topages/twiststrip.php

And look at today's special price at the bottom of the page!!!

Wink -john-
can you believe it!
I stumbled on it while looking for unshielded tefzel insulated twisted pair (which I'm still looking for).
[quote] From: owner-aeroelectric-list-server(at)matronics.com [mailto:owner-aeroelectric-list-server(at)matronics.com] On Behalf Of John Loram
Sent: Sunday, April 29, 2012 4:31 PM
To: aeroelectric-list(at)matronics.com
Subject: RE: AeroElectric-List: Secrets Techniques

Well, that works like a charm!... I've spent so many years trying not to melt the insulation that I was not taking full advantage of the properties of Tefzel. I've encountered solder sleeves in the past, but never appreciate their purpose.

onward and upward (someday), -john-

Quote:
From: owner-aeroelectric-list-server(at)matronics.com [mailto:owner-aeroelectric-list-server(at)matronics.com] On Behalf Of Robert L. Nuckolls, III
Sent: Thursday, April 19, 2012 9:39 PM
To: aeroelectric-list(at)matronics.com
Subject: Re: Secrets Techniques

At 11:12 PM 4/19/2012, you wrote:
Quote:
Sixty years I've been doing this! Built all my own ham radio gear as a teenager in the 50's, got a EE degree from a prestigious university, spent my adult life as a development engineer designing medical and laboratory instruments. You'd think I could strip a multiconductor shield Tefzel insulated cable in my sleep, but it's a bit(at)h ([email]bit(at)h[/email])! I make a mess of the shield when I try to remove the Tefzel. What is the secret trick to it!

The secret is go ahead and 'trash' the shield.

I have a bunch of 22AWG, 3-conductor shielded
that a common Stripmaster more-or-less strips
the outer jacket and probably 80% of the shield
strands. Then I use a solder-sleeve
to put a neat pigtail on the damaged shielding.

There are normally no currents flowing in the
shield. If your grounding pig-tail gets good
electrical connection with only one of of the
strands, you're good to go. More than likely
you can get good connection with 10% or more
of the shield stranding. The neat thing
is that the pigtail under heat shrink covers
the carnage.

I'll see if I can dig some of the stuff up
and do a comic-book series of pictures on the
process tomorrow.



Bob . . .
Quote:


href="http://www.matronics.com/Navigator?AeroElectric-List">http://www.matronics.com/Navigator?AeroElectric-List
href="http://forums.matronics.com">http://forums.matronics.com
href="http://www.matronics.com/contribution">http://www.matronics.com/c


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href="http://forums.matronics.com">http://forums.matronics.com
href="http://www.matronics.com/contribution">http://www.matronics.com/c
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PostPosted: Sat May 05, 2012 4:33 am    Post subject: Secrets Techniques Reply with quote

I knew there must be a tool for this!!!

http://www.aircraftspruce.com/catalog/topages/twiststrip.php

And look at today's special price at the bottom of the
page!!!
Cheap!!! I have 2 on order, so I will always have a backupâ˜ș
Roger

Do not archive


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PostPosted: Sat May 05, 2012 5:28 am    Post subject: Secrets Techniques Reply with quote

At 07:30 AM 5/5/2012, you wrote:

Quote:
I knew there must be a tool for this!!!

http://www.aircraftspruce.com/catalog/topages/twiststrip.php


Hadn't seen this one. Your find reminds me that
I haven't a clue as to how this task was handled
at any of TC factories I worked at. I don't recall
that I ever had cause to visit the wire-slingers
for a close look at how they did things. All of
my contact with their work product was after it
got installed on an airplane.

I've still got a badge for Hawker Beech but they
shipped their wire fab shops to Mexico about 10
years ago . . . I'll have to seek insight to those
processes elsewhere but I'll see what I can learn.
Bob . . .


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PostPosted: Sat May 05, 2012 5:29 am    Post subject: Secrets Techniques Reply with quote

Quote:
Wink -john-
can you believe it!
I stumbled on it while looking for unshielded tefzel insulated twisted pair (which I'm still looking for).

I've got a few thousand feet of two
conductor 22AWG shielded. I probably
ought to list it in my catalog. Will
22AWG work for you and how much do you
need?



Bob . . . [quote][b]


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jloram



Joined: 07 Nov 2009
Posts: 54
Location: United States

PostPosted: Sat May 05, 2012 10:18 am    Post subject: Secrets Techniques Reply with quote

Oh, please don't use any time better spent enjoying your grandson!

-john-

[quote] --


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PostPosted: Sat May 05, 2012 10:27 am    Post subject: Secrets Techniques Reply with quote

I'm just looking for 15 ft of UNshielded twisted pair for the RS-422 data lines in a Dynon D10A installation. If I can't find it, I'll just twist some 22 AWG, but would prefer to have the Tefzel casing for a little added physical protection.

Shielded I got already. but thank you, -john-

(I wonder if there's tools for stripting three and four wire versions of the shielded twisted shielded cable?)

[quote] From: owner-aeroelectric-list-server(at)matronics.com [mailto:owner-aeroelectric-list-server(at)matronics.com] On Behalf Of Robert L. Nuckolls, III
Sent: Saturday, May 05, 2012 6:29 AM
To: aeroelectric-list(at)matronics.com
Subject: RE: Secrets Techniques

Quote:
Wink -john-
can you believe it!
I stumbled on it while looking for unshielded tefzel insulated twisted pair (which I'm still looking for).

I've got a few thousand feet of two
conductor 22AWG shielded. I probably
ought to list it in my catalog. Will
22AWG work for you and how much do you
need?

Bob . . .
Quote:


href="http://www.matronics.com/Navigator?AeroElectric-List">http://www.matronics.com/Navigator?AeroElectric-List
href="http://forums.matronics.com">http://forums.matronics.com
href="http://www.matronics.com/contribution">http://www.matronics.com/c
[b]


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nuckolls.bob(at)aeroelect
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PostPosted: Sat May 05, 2012 2:44 pm    Post subject: Secrets Techniques Reply with quote

At 01:26 PM 5/5/2012, you wrote:
Quote:
I'm just looking for 15 ft of UNshielded twisted pair for the RS-422 data lines in a Dynon D10A installation. If I can't find it, I'll just twist some 22 AWG, but would prefer to have the Tefzel casing for a little added physical protection.

Shielded I got already. but thank you, -john-

then use it. it will be fine . . .


Bob . . . [quote][b]


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aerobubba(at)earthlink.ne
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PostPosted: Sun May 06, 2012 3:56 am    Post subject: Secrets Techniques Reply with quote

Hi Bob-

WRT techniques for dealing with tefzel, Basler up in OSH comes to mind. When they do a turbine conversion, every wire, tube, hose, and threaded fastener comes out. It's quite process, and they build up their own harnesses right there in their electrical loft.

Glen Matejcek


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nuckolls.bob(at)aeroelect
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PostPosted: Sun May 06, 2012 5:38 am    Post subject: Secrets Techniques Reply with quote

At 06:54 AM 5/6/2012, you wrote:
Quote:

<aerobubba(at)earthlink.net>

Hi Bob-

WRT techniques for dealing with tefzel, Basler up in OSH comes to
mind. When they do a turbine conversion, every wire, tube, hose,
and threaded fastener comes out. It's quite process, and they build
up their own harnesses right there in their electrical loft.

Sure. Tefzel has been the insulation of choice
in GA aircraft (and most military) since the
early 80's.

I had the electrical-avionics group on the
Gates-Piaggio GP180 program at Lear. We
were considering Tefzel for that program
and discovered it required an State
Department technology export license if
we were going to use it in airplanes
sold outside the country.

A good friend of mine was a tech-rep for
Raychem who was offering an alternative
to Tefzel in their "Spec 55" wire. I brought
in some samples and the folks on the wire
balcony were playing with it when it was
announced that Lear had acquire the necessary
export license. The changeover to Tefzel was
pretty much a foregone conclusion in all
the TC aircraft.

Tefzel (or ETFE) is a cousin to Teflon
(PTFE) and is widely used in many technologies
besides wire. See:

http://tinyurl.com/24stb9e

http://tinyurl.com/yb462g6

It's not a really big deal for stripping
except when working with thin overlays
that (1) buckle in column load when
you try to push it off (2) a braided
structure with a very strong grip
on the insulation.

Bob . . .


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jloram



Joined: 07 Nov 2009
Posts: 54
Location: United States

PostPosted: Sun May 06, 2012 9:42 am    Post subject: Secrets Techniques Reply with quote

Yeah, I know. Just being anal.... I'll use it, thanks, -john-

[quote] From: owner-aeroelectric-list-server(at)matronics.com [mailto:owner-aeroelectric-list-server(at)matronics.com] On Behalf Of Robert L. Nuckolls, III
Sent: Saturday, May 05, 2012 3:42 PM
To: aeroelectric-list(at)matronics.com
Subject: RE: Secrets Techniques

At 01:26 PM 5/5/2012, you wrote:
Quote:
I'm just looking for 15 ft of UNshielded twisted pair for the RS-422 data lines in a Dynon D10A installation. If I can't find it, I'll just twist some 22 AWG, but would prefer to have the Tefzel casing for a little added physical protection.

Shielded I got already. but thank you, -john-

then use it. it will be fine . . .


Bob . . .
Quote:


href="http://www.matronics.com/Navigator?AeroElectric-List">http://www.matronics.com/Navigator?AeroElectric-List
href="http://forums.matronics.com">http://forums.matronics.com
href="http://www.matronics.com/contribution">http://www.matronics.com/c
[b]


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