Tuesday, December 11, 2012


At this point, we address the wire itself. Cut off a piece of wire three turns around the spool and place on the ground. The diameter of the loop is called the cast of the wire. The surplus material I have has a twenty two inch cast and a very high tensile strength. Another way of saying it is very tough to work with. To make the wire more amenable, a wire straightened is modified to be be used as a wire bender or preformer. The new cast will form a circle very close to the conduit diameter, approximately 4 1/4".
The torque supplied by the over-sized head stock is enough to pull the wire through the bender to the tube form.



Inches per Pound of Wire



        Wire
    Diameter
                                                                  Silicon                                                Stainless
                                      Aluminum           Bronze         Copper       Nickel          Steel

.020 "                               32,400               10,300             9800          9950            10950
.025 "                               22,300                7100               6750          6820             7550
.030 "                               14,420                4600               4360          4400             4880 
.035 "                               10,600                3380               3200          3240             3590
.040 "                                 8120                 2580               2450          2480             2750
.045 "   3/64 "                    6410                 2040               1940          1960             2170
.062 "   1/16 "                    3382                 1070               1020          1030             1140
.078 "   5/64 "                    2120                  675                 640             647              718
.093 "   3/32 "                    1510                  510                 455             460              510
.125 "    1/8 "                      825                   263                 249             252              279
.156 "   5/32 "                     530                   169                 160             162              179
.178 "   3/16 "                     377                   120                 114             115              127
.250 "    1/4 "                      206                    66                   62               63                70
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