Humbucker hookup wire

[Woodenspoke]

I have my first few humbucker bobbins ready to assemble however I am having some startup issues. I have started with a 28awg thickness hookup wire and to me it seems very large and stiff. Trying to pack in a wire that big around the coils seems a monumental task.

I know this is basic stuff but how and what are you using or doing to get all those wires hooked up into such a small space.

If you are using a smaller wire do you have suppliers link for spools.

Thanks

[Peter Naglitsch]

I use AWG 28. Works fine. But I use a multi strand, very flexible wire with quite thin insulation, thus not creating a bulk. I have to keep the heat low not to melt the insulation thou...

[Woodenspoke]

If the wire melts most likely it is some sort of wire from a crimp situation like cat 5 wire. I dont want to use cat 5 wire.

My wire is stranded and pre tinned.

What I wound up doing is just pull out the leads on the main cable so I no longer had to tuck anything anywhere. But it still seems to me such a basic function of building PU's such as a final hookup of the bobbins should be covered somewhere.

I started looking at 32 awg Teflon wire but it is expensive.

Again if anyone has any suggestions for wire sizes and US suppliers please chime in here. I know its not very interesting but your input would be appreciated.

[David Schwab]

If the wire melts most likely it is some sort of wire from a crimp situation like cat 5 wire. I dont want to use cat 5 wire.

What are you talking about? PVC insulation melts if you heat it up too much. I also use 28AWG wire. It's not CAT 5 wire, just multi stranded beldin wire. It's not stiff. I get my wire from Mouser.

What I wound up doing is just pull out the leads on the main cable so I no longer had to tuck anything anywhere. But it still seems to me such a basic function of building PU's such as a final hookup of the bobbins should be covered somewhere.

What main cable? Are you connecting the hookup cable right to the bobbins?

Getting the wires to fit in a humbucker is a pain in the ass. I lay the main hookup wire down along the side of the baseplate where the hole is, and solder the ground wire on the baseplate. Then you just have to attach the leads to the hookup wire and try to tuck everything in somewhere.

Just look at a few commercial pickups and see how they do it.

I can see why some companies are using a PCB on the bottom to connect the wires.

[Peter Naglitsch]

Yeah, the PVC jacket on a hoockup wire with a thin insulation will melt at a pretty low temp. That has nothing to do with that wire being ripped out of a CAT5 LAN-cable or anything. It's a standard wire and the PVC will melt if heated to much. Simple as that.

Let me google that for you
Number five is in CA.

[belwar]

Allied Wire & Cable Inc
101 Kestrel Drive
Collegeville, PA, 19426

1-800-828-9473

Part Number: 61-28-7T-0
Description: 1061 28 Awg 7 strand Black.

Pretty darn PAF accurate.

This is the wire used to solder to your start, and end wire on your bobbins.

[Woodenspoke]

What are you talking about? PVC insulation melts

Not all wire is made the same and I was referring to the previous poster. I certainly know that some wire sheathing melts real fast and others have a higher melting point. Most hook up wire is made to be soldered... CAT 5 wire is not.

Getting the wires to fit in a humbucker is a pain in the ass

The point of this post is to find out what others have done to solve this PIA issue

What main cable? Are you connecting the hookup cable right to the bobbins?

No that would be insane. But I am finding the 28 Awg to be a tad larger than I expected for a bobbin lead. The first lead is tucked into the bobin using the bottom hole and the bobbin wound on top of it. Second the finishing lead wire also seems very big even under the tape. A smaller more flexible bobbin lead wire would be a better choice. Or maybe I am expecting too much and a stranded 28 AWG is fine?

Just look at a few commercial pickups and see how they do it

Most of my spares are single coil the rest have either covers are on working guitars. Sadly the single coil method seems a bit easier to manage. A Humbucker with eyelets????

you just have to attach the leads to the hookup wire and try to tuck everything in somewhere.

The millon dollar question Somewhere....I finally just shortened the run so I went straight from the bobbins to the main cable no folds and taped over the outside assembly. I cant say it filled me with joy but it was almost invisible but a pain in the ass..

[David Schwab]

Not all wire is made the same and I was referring to the previous poster. I certainly know that some wire sheathing melts real fast and others have a higher melting point. Most hook up wire is made to be soldered... CAT 5 wire is not.

That's true. The wire I use doesn't melt very quickly. I have my iron set to 650° F.

The point of this post is to find out what others have done to solve this PIA issue

I haven't solved it. But then, I don't make many humbuckers. I use circuit boards on my own pickups.

Just keep your leads as short as possible. Then you wont have much wire to tuck.

No that would be insane. But I am finding the 28 Awg to be a tad larger than I expected for a bobbin lead. The first lead is tucked into the bobin using the bottom hole and the bobbin wound on top of it. Second the finishing lead wire also seems very big even under the tape. A smaller more flexible bobbin lead wire would be a better choice. Or maybe I am expecting too much and a stranded 28 AWG is fine?

28 is what most people use. That's what they sell at Stew-Mac too.

The very first humbucker I did, I wanted to pull my hair out. It gets easier the more you do. You either have to look how others to it, or find your own way.

OI run my leads out on one end of the bobbin. I used to use the holes, but I stopped doing that.

Most of my spares are single coil the rest have either covers are on working guitars. Sadly the single coil method seems a bit easier to manage. A Humbucker with eyelets????

You can do that, if you have your bobbins set up for it. Check out the Tom Anderson pickup pictures below.

Some other pickup makers have molded contacts into their bobbins.

[Woodenspoke]

I also solder with a high temp Hakko station, or at least I set the temps high so I can get the job done quickly. Soldering isn't the issue, maybe I need tiny hands and fingers..LOL

Some other pickup makers have molded contacts into their bobbins.

If I continue to have issues I could always make some non conductive bushings(phenolic) with an eyelet in the center and glue that into a hole drilled into the plate.

I guess I will have to weight the lathe time VS cursing at my bobbin leads.


Does anyone havea good source for wire. Been having an issue finding good prices on 2, 3, and 4 conductor braided sheath cable. Or has anyone found a source for the braid to make up their own cables. Also a source for smaller teflon wire under 28 AWG?

I found some inexpensive foil sheilded cable with drain but the wire itself is not what I needed as it has a low melting point sheathing. I am not crazy about pushback wire so a standard wire is fine.

thanks

[Peter Naglitsch]

The first lead is tucked into the bobin using the bottom hole and the bobbin wound on top of it.

There are other, IMO better ways...

[Woodenspoke]

There are other, IMO better ways...

Is it a secret?

[Dave Kerr]

Lots of stuff in here regarding wire sources, stripping tools, 3rd hand improvised tools, etc. Try searching on humbucker pigtail. No mention anywhere I can see of easy and elegant tips/tricks on tucking/securing the pigtails/leads. Rather than people keeping trade secrets close to the vest, perhaps there's not much to improve on the PITA method you've settled on.

[Woodenspoke]

Rather than people keeping trade secrets close to the vest, perhaps there's not much to improve on the PITA method you've settled on.

If I have settled on this method its only because I have no other ideas other than what David has mentioned. There must be a Swedish method but that seems to be hush hush.

Hey I have no problem trying something new. Some constructive suggestions even explanations of the PITA method you use. I find after the first dozen pieces of any project people finally start getting the hang of it or figure out a better method. Maybe you hire someone else to do the PITA work?

Is it just too basic of a question to put to all of you experts. maybe if I had Lollars book its mentioned but I cant afford $200...lol

[SJE]

The thing with Cat 5 cable is it's solid copper - so it transfers heat real quick so also melting the PVC sleeve further. Also being solid copper it inflexible and will make life so much harder when trying to mount the bobbins on the base plate.

For me I when I start a bobbin wind my procedure is:

1) Solder the pigtail to the magnet wire
2) Push the pigtail through the hole and then using a small length of the black tape secure the pigtail to the inside of the bobbin - making sure that the magnet wire comes out in the direction it will be wound.
3) Attach bobbin to winder . . . and away you go.

[Dave Kerr]

I've assembled a grand total of 3 PAF style humbuckers, if I had an answer for you I'd tell you. Well, a couple hours ago I would have - now, maybe not.