This is a continuation of a post on this topic I made last Spring:
Remote key system (http://www.foreforums.com/index.php?topic=12550.msg65969#msg65969)
As shown in that post, the actuator wires that run from the coach to the door are constantly bent and smashed. This leads to breaks in the wires. I was able to repair the wires last Spring only to have them fail again a couple of weeks ago. I got to thinking that there must be some type of wire that is made for such situations. So I "Googled" ultra flexible wire and sure enough there is a wire like this made by Daburn:
#2671 Ultra Flexible Sub-Miniature Wire - U/L STYLE 1568, 1692 (http://www.daburn.com/2671UltraFlexibleSub-MiniatureWire-U/LSTYLE15681692.aspx?gclid=CJus4bD2ha0CFcoaQgodQ0IVRg)
The only problem is that Daburn only sells 100 foot lengths for over $200. So I emailed them to see if they knew of a supplier that sold this product by the foot. Daburn referred me to McMaster-Carr. See flexible wire:
McMaster-Carr (http://www.mcmaster.com/#electrical-wire-cable-and-cords/=fdshco)
It cost $2.75 per foot for the 20 gauge wire (4.75 amps), but it seemed a reasonable price if it would solve my problem. The wire has 266 very fine strands (see photo below).
After I got the wire, the repair was fairly easy. I had to remove the inside door face to get the lock back together, but I had to do that anyway because a tear (behind the handle) that needed to be repaired. Special thanks to another Foreforums member (Karl Brenneman) who helped me get the lock back together!
George
Great find. I have had to repair a docking light on a bay door, same break, same cause. I was able to extend the wire some to take some of the strain off the system.
Your solution is way better. Looks like a nice multi coach project for some group that buys a whole roll to share.
Nice find and writeup George! Thanks.
see ya
ken