Hookup Wire

Solid vs. stranded

Why not just get cheap, bulk solid of Amazon? Go for it…

I started off using only solid core from a few vendors different mainly by insulation thickness (and thus the wire’s overall diameter), then for a higher temp-resistent insulation. Ultimatley I found PTFE (teflon) instead of PVC insulation ideal, but more difficult to procure as solid core. As a result, and after trying dozens of variations, I settled on PTFE, silver-tinned stranded (TubeDepot) and haven’t looked back (albeit a bit late in the build).

  • Solid generally holds its shape whereas stranded does not
  • However, tinned stranded, particularly silver-tinned, holds its shape essentially as well as solid.
  • Solid is much more suspectible to fatigue and overall breakage, especially from nicks and with smaller gauages in confined areas where you’ll be moving wires for access. I had a small gauge tube socket wire snap (appeared to have been nicked) and right then realized stranded probably would have held up.
  • Spent a fair amount of time trying different wire from various vendors, namely Mouser.
  • Insulation was the main driver at first
  • Ultimately tried stranded simply because I could not find much PTFE-insulated solid.
  • Very pleased with TubeDepot’s PTFE-insulated, silver-tinned, “aerospace grade” wire.
    • “PTFE” is teflon and impervious to soldering temperatures
    • 18, 20, and 22 AWG
    • Relatively inexpensive (no need to order minimum 1000’ spools…)
    • Exceptional performance soldering, bending, etc.
    • There’s also “Tefzel”, but can be very difficult to strip without thermal strippers.
  • A succinct wire types & sizes overview from Mojotone.

Tip: Hammond transformers and chocks use untinned stranded, which I found a bit frustrating especially for the 6V3 lamp holder lugs…splice in some better and long lengths of 18 AWG stranded.

Tinning Stranded Wire

  • None:
    • Just asking for problems, and tinning yourself is a hassle
    • Tip: Tin just the very tip to retain the pliability
  • Tin: Better
  • Silver: Best

Insulation material

  • PVC melts
  • PTFE (teflon) does not

Aesthetics

Shielded Wire

Off the shelf

  • Mogami

DIY

  • Make your own
  • Use the “ground drain” technique; easier and cleaner than bunching the mesh
  • Snip using precision scissors (over a trash can)

Crimping

  • Generally avoid it…
  • May be tempting, especially for switches, but crimping is simply not the same as soldering…

What I use

  • Primary side: 18 AWG, thick PVC solid (for aesthetics)
  • Everywhere else: 18, 20, or 22 AWG “aerospace grade, PTFE, silver-tinned stranded”

Wire: PTFE (teflon) insulated silver-tinned stranded. o PTFE: Will simply not melt o Silver-tinned: Pre-tinned holds its shape, and silver tinning makes soldering a cake walk o Stranded: Much more resilient to flex fatigue, and these wires will need to flex as you’re moving them around confined areas.