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Discussion Starter · #1 ·
Rewiring my triumph, and want to hide as much of the wiring I can. Any tips on getting the wire from point a to b? I tried coat hangers, not much luck. I am trying to keep the holes I drill in the downtube (where most will be hidden) as small as possible. I would assume a rubber grommet in frame hole to keep from chafing and shorting out wires?

Any "secrets" would help.
Thanks,
Erron
 

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I used a base guitar string. Has spring to it so it doesn't bind up and it also has a little ring on it which you can use to attach your wires to after you've fed it through the frame. Use safety wire (like for safety wiring nuts and fasteners) to attach your wire to the guitar string. Then tape it well with electrical tape to keep it streamlined. Yes, use some kind of grommet or heavy wrap to prevent shaffing. It also helps to use soluble wire lube for pulling wires through conduit. Works awesome! No binds, no breaks! Be careful where you drill holes obviously too. Tedious!! Have fun!! Do you have a hardtail on your Triumph? If so, how are you going to run the wires through it? I never came up with a good solution for my hardtail wiring.
ratwagon said:
Rewiring my triumph, and want to hide as much of the wiring I can. Any tips on getting the wire from point a to b? I tried coat hangers, not much luck. I am trying to keep the holes I drill in the downtube (where most will be hidden) as small as possible. I would assume a rubber grommet in frame hole to keep from chafing and shorting out wires?

Any "secrets" would help.
Thanks,
Erron
 

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make the holes bigger then needed. deburr them. use grommets, a thin strong wire ( i used a hanger and some welding wire), a flashlight, and some long ass needle nose, some dental tools/picks. Add to that a bit of creativity :) badda bing-badda boom!
ratwagon said:
Rewiring my triumph, and want to hide as much of the wiring I can. Any tips on getting the wire from point a to b? I tried coat hangers, not much luck. I am trying to keep the holes I drill in the downtube (where most will be hidden) as small as possible. I would assume a rubber grommet in frame hole to keep from chafing and shorting out wires?

Any "secrets" would help.
Thanks,
Erron
 

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Here's some tips--I've internally wired three bikes now, so I'm no expert:

(1) Whatever size you think you need the hole to be, make the hole two drill sizes bigger, because you will be pissing and moaning if you don't.

(2) You should use the grommets, but not if the holes will be too big after complying with point (1) above. Using those grommets increases the size of the hole quite a bit. How big is too big, you ask? Fuck if I know--like obscene porn, I know it when I see it.

(3) Make sure you smooth out the hole with a file both inside and out so that the wire won't snag (this obviously is more crucial if you aren't using grommets). I also bevel the holes slightly in the direction the wire enters the hole.

(4) Map every wire out on the bike BEFORE you start drilling holes. Have your wiring diagram out so you don't fuck it up.

(5) I use baling wire/picture hanging wire to run through the frame. Coat hanger wire is WAY too thick. I run the baling/picture hanger wire so that it sticks out from both ends of where it needs to go and just tape or tie the electrical wire to one end and pull it through. Try not to run too many wires through one hole, that makes the whole job a huge pain. I try and limit it to three 16g or 18g wires per hole or less.

(6) Heat shrink wrap the wire where it comes out and goes in. Also, use bullet connectors at both ends so you can fix/move/adjust your light/battery/coil/ignition without cutting up or otherwise clusterfucking your wires.

I'm sure I've forgotten lots of other stuff, I'm sure others will pipe in. I am also confused as to why wire would go in the downtube as opposed to the backbone, but I'm sure you have your reasons.

ratwagon said:
Rewiring my triumph, and want to hide as much of the wiring I can. Any tips on getting the wire from point a to b? I tried coat hangers, not much luck. I am trying to keep the holes I drill in the downtube (where most will be hidden) as small as possible. I would assume a rubber grommet in frame hole to keep from chafing and shorting out wires?

Any "secrets" would help.
Thanks,
Erron
 

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I use a peice of twine with a knot tied in the end.Blow it thru with the air nozzle.Then tie that to a piece of welding wire...then soldier that to the wires you want to pull thru.A 3 step process that works well for tight bends and weird turns.
 

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You can suck a piece of string through with a vacuum cleaner, no kidding, it works. Tie your wire to the string an gently pull it through.
 

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Discussion Starter · #7 ·
I am also confused as to why wire would go in the downtube as opposed to the backbone, but I'm sure you have your reasons.[/QUOTE]

That's what I meant, backbone. As far as the hardtail, I only have two wires going to that section for my brakelight, so I am going to weld on some car brake line and run them through that.

Lotsa good tips, thanks everyone, I really dig the vacuum/string idea, going to have to try that first.

Keep them coming,
thanks, Erron
 

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VonSwanko said:
I use a peice of twine with a knot tied in the end.Blow it thru with the air nozzle.Then tie that to a piece of welding wire...then soldier that to the wires you want to pull thru.A 3 step process that works well for tight bends and weird turns.
yep me too
 

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On my car any wires that I tried to hide (not many) I had read somewhere on how you should ALWAYS do a kleenex test on any hole you feed a wire through. If it snags you will have trouble grommet or not. I mean it is a hard tail and vibrations are there and apparent more so than on a bike that has shocks. So if you are keeping it tight and clean use some Plasti-dip (that stuff you dip tool handles in) on your de-burred holes it will bond well and is built for tough work jobs. But make sure to do the tissue test before you coat the hole. Unless you are building this to sell and don't care if it shorts out and catches fire. Grommets are cool but I never find the size I need and that Plasti-coat stuff works like a champ! I have even used it to dip the cracked coil pack on my 91 VW so it would get the spark to the plug. And the last I saw that car it was still running with no problems. Good luck
 

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I agree with Trent.It sure looks cool as hell,but it's awful hard to find your shorted wire inside the down tube with a 12 pack in your gut,a half dead Mini Mag and the State Patrol "just checking on you".Especially if you have an old bike----leave that for the show bikes.

Jimmy Diesel
 
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