What gauge wire do I need?

Flashlight Modding and DIY Parts
1

I have a few budget lights that I need to mod, change emmiters etc, so I thought I would get some silicone wire as they are generally very thin.

The question is what gauge should I get?

Cheers,

Marc

2

I use 18-22 AWG wherever possible and if it fits. for springs I use copper braid.

also depends on how many amps you are running the lights at?

3

Awg22 is a nice compromise between high current and ease of use. For 3A or less even smaller is ok. For absolute max you need whatever you can fit since at that point mOhms matter. Spring bypasses make more difference than a small change in wire guage. In some instances you can simply double up on wires instead. Also, Teflon coated wire is both tougher and thinner than the same guage silicon wire and you don’t always need the flexibility.

4

Thanks for the replies.

I will probably be running a max of 3a but maybe a little more.

Where do you guys get you wire? I was looking at fasttech.

Marc

5

I really like the wire Mountain electronics sells.

The wire ILUMN sells is pretty good also…
“http://www.illumn.com/leds-drivers-optics-mcpcbs.html?*store=default&cat=73”:http://www.illumn.com/leds-drivers-optics-mcpcbs.html?*\_\_store=default&cat=73

6

I put the wire into my cart at every other order from HobbyKing. reasonably priced, intended for R/C use but also great for lights.

I avoid aliexpress because I typically don’t need the entire lot.

7

Problem is the shipping. I’m In France.

Marc

8

I am sure France has decent electronic parts stores where you can order from. it is wire, after all.

edit: if everything fails try ebay. bought wire last year and it was an ok deal. I think it was ebay HK.

9

I just bought some silicon wire yesterday from China with free shipping….just go to eBay.com and search for silicon wire awg22 or similiar.
And if you don’t have it already buy some flux, I am happy with the kester flux pen 186. It make soldering a lot easier and the pen is nice to use.

10

I have plumbers flux. I guess its the same thing. I have done a lot of soldering in my past life, I used to make XLR leads.

I will search ebay, thank you.

11

It’s not. Don’t use plumbing flux on electronics. It’s acid.

12

OK, I thought it was the same stuff.

13

For a long time I didn’t know about that either and when I look into my older stuff I see green.

14

Acid flux will eat the thin PCB traces away and it’s nearly impossible to clean 100% of it off so the remnant will do it’s nasty deed anyway, only later.

Phil

15

Ok, i see. I will get some proper flux.

By the way, just ordered 5m 20awg silicone wire from eBay for $2 shipped. That’s a lot cheaper than fasttech. So thanks everyone.

Marc.

16

There seem to be some differences in all the silicone wire, some solder better some are a bit more rigid(still soft compared to everything else) and some have slightly bigger insulation. Some deliver in 1m parts and some in the length you order in one piece, some say 5m and show a black and a red wire but deliver only 2.5m of each.
All in all I am quite happy with all my wires because they don’t melt when soldering.

Banggood has the kester flux pen I use, I couldn’t find it on eBay for reasonable shipping anymore so I have one on order but it has not arrived yet.

17

I got these:

http://www.ebay.com/itm/321825007955?redirect=mobile
https://www.fasttech.com/products/3496700

18

I had a problem as fasttech wanted extra shipping as they could not ship liquids even though its a paste.

19

The silicone-insulated wire at ME is more expensive, but good quality. The insulation seems more durable than the cheaper options.

I also have some wire from Fasttech. Although not bad, the insulation is softer and cost me an expensive multi-meter fuse (red wire got nicked going though the pill, not a good idea to do the first power up with high-current cells.)

Teflon wire is actually thinner than silicone wire of the same gauge and can take higher temperature. The insulation is also much tougher, but the wires are much less flexible.

22 awg is rated for 7 A to 13 A for a single conductor, depending on the temperature rating of the insulation and application. (But the wire will get hot if you try this!). Resistance is about 0.005 ohm for 10 cm. Above 4 or 5 A I would go to a bigger gauge.

20

I got 20awg. I thought it would be a good choice, not too thick to work with.