I have a lot of different wires that are enameled ranging from 17 - 32g and I need to make some 0-4g wire bundles. I was thinking of using what I had which is primarily 28-32g (probably won't need 17g) and stretching them really tight then twisting. Is there any problem with this or any problem with the different size gauges? The enamel will be removed at the very end of the wire and soldered together once it is twisted. I'd like to keep the diameter of the wire as small as possible which is why I am using this enameled wire so I can not use any insulation.

 

What is the function/application?
Are they ran in cable trough?
Max.

 

Copper is copper so I don't think there is any problem. You _might_ get a little better packing density _if_ you can keep the small gauge wire in the gaps of the larger gauges.

 

Copper is copper so I don't think there is any problem. You _might_ get a little better packing density _if_ you can keep the small gauge wire in the gaps of the larger gauges.

That was what I was going to try but when the twisting starts it kind of gets tough to keep them in place.

 

IMO the question cannot be answered without knowledge of the application, what voltages are involved etc, also whether it is going to be used in equipment subject to CSA, UL, EU environment and/or regulations.
More detail is required to give a objective answer!
Max.

 

Seems like a lot of trouble to avoid buying the right wire in the first place.

 

I have a lot of different wires that are enameled ranging from 17 - 32g and I need to make some 0-4g wire bundles.

If you want to take 32g of wire and divide it into bundles of 4g, then you need to cut the wire into 8 pieces of equal weight, and if all the wire is the same diameter, then cut it into 8 pieces of the same length. Then bundle the pieces into eight 4g spools.

 

Copper is copper so I don't think there is any problem.

Except of course when you need to consider the skin effect at higher frequencies.

 

Seems like a lot of trouble to avoid buying the right wire in the first place.

Agreed but I have yet to find large gauge (fine stranded) enameled wire. The reason for using the enameled wire is to not need insulation as it takes up almost as much space (in some cases more) than the wire. Another reason is that I have thousands of ft of 26 - 32g enameld wire in 300+ ft lengths so I would like to use this if possible.

As for the questions about application, there are a number of intended applications but it will carry 48-50 VAC max and as low as 2.5-3 VAC. As for frequency, it will operate at 50-60 Hz - does skin effect come into play at these frequencies? As to the question about regulations, no, this won't be subject to those as it is a personal project. It will be used in a transformer in one case and as a bus through tight/sharp angled housing.

I'm considering trying a different approach than twisting, at least when making multi-strands of 4g bundles. I've seen wire that uses a nylon wrap that twists around the wire and about every inch the thread passes under the thread and pulled back the other way (like knotting) and on up the wire - this alternates direction every inch or so and cinches the wire tight.

 

Sounds like you are describing a very old technique know as Lacing?

Max.

 

If your worrying about the "space" this bundle of wires will take, I'm pretty sure a hand bundled group of wires the has the equivalent size of 4Ga wire, is going to be larger and 'messier' than a single standard 4Ga wire. Before making one of the correct length you will need, maybe you should make a short one, say ~1foot or so long to see how big it will be.

 

Twisting enameled wire may take off the enamel, creating a short. As stated before, more info is necessary. Because each individual strand will carry the voltage and amperage, the size wiring you use is rather small. Did you think of using a circuit board in place of the wiring?

If your idea is only to use a stranded set -up, try using polyurethane. The kind used on furniture.