If you’ve seen the “stuff in my drawers” thread, you know that I like wires, probably more than I should:
However, it always seems like regardless of how many wires you have, you never quite have the right kind, size or color that you need. I’m not going to list all the different kinds of wire I have, but here are some recommendations:
Regular plastic-coated wires aren’t particularly helpful for building sabers, or anything else that requires soldering. When you solder these wires, the coating tends to shrink or melt and cause “goose-neck” soldering joints that can cause shorts. These wires are fine for crimping though.
Silicone doesn’t melt, and it’s much more flexible than regular plastic, which makes for nice and easily workable wires. Unfortunately the silicone is not quite as resilient as the plastic, so they make the silicone coat a little thicker. This can be a big problem in a saber where space is tight.
PTFE also doesn’t melt, and it’s quite durable, which means that the coating can be thinner than plastic wire, especially if you can find wire that is rated for less than 600V. (The higher the voltage rating, the thicker the coating, but we don’t need 600 volts for making sabers) Most PTFE wire is also mil-standard with tin- or silver-coated strands which makes it really easy to solder. The wires tends to be somewhat stiff, so bending them into shape can be a little extra work. Generally, these are the right wires for making sabers.
I use this stuff when making string blades. Granted, it’s been a while since i made one of those.
If 30 AWG ptfe wire is still too thick, consider magnet wire. Magnet wire has a super-thin coating, and come in seriously thing wires. I haven’t actually used this particular wire yet, and it can only carry enough power for buttons or single LEDs, but it’s about the thickness of human hair. That spool is actually a sewing bobbin!
Ribbon cable is unfortunately regular plastic cable, but it’s great for keeping your wires organized. It can be super convenient to peel of 3 or for 4 wires to use for buttons + gnd.
Then there is the whole issue of connectors, but that’s a story for another time…