Shortening Wires

[jasonf150]

Hey I wanted to see if anybody was doing this. Once I find the final location of all aspects of my ebike, mainly the controller, I'd like to remove all the excess wire. Does anyone else do this? Right now I have the wires wrapped around the velcro straps for my frame bag. I think it'd make a much cleaner look to get rid of all the extra wire.

[motomech]

Until you gain more experience, I would recommend against it.
I shot myself in the foot "shortning" the wires on my first build.
I had hidden the controller under the seat and while it was totally out of sight, but I had to stuff the assortment of "cheap kit" connectors and extra wire into a camera case and I didn't like the look of that.
Rashly, I started clipping the connectors, only to find that I needed to learn what connectors I wanted to use, then get them and various accessories and tools ordered, etc. I got side-tracked and when I got back to it, I had forgotten where all the "rat's nest" of wires went. That controller was somewhat unique and I couldn't find a diagram, so I was trying various combo.s when I fried the Hall sensors in my motor
This time around, A little wiser, I'm stuffing everything into a small mesh handlebar bag.
Even though I am now more versed and supplied with connectors, etc., I'm not going to mess with them until I'm sure on the final configuration. Which motors, controllers[I have a bunch now], controller locations, etc. Depending on which controllers I settle on and what features of the C.A. I end up using is going to change some things, I'm sure. I may even want to "beef" up some phase wires which would be the time to re-do the entire harness.
I am assembling and testing this week and should have some pic.s towards the end of the week.
Can you coil the extra wire up and pplace it the frame bag for now? Or does the controller location prohibit that?

[neptronix]

No problem doing it, this is basic electrics

Make sure you have some heat shrink beforehand to keep it clean. If you are dealing with power wires ( thick stuff ), you will want to solder up things or find a good securing method to link up the shortened section.

[jasonf150]

I can't fit the wires into the bag because the battery takes up about 98% of the space in the bag.

[motomech]

Nept.
You have at this for a while and have forgotten what it's like to be noob. And you have a bunch of "stuff" lying around
Even once I decided what connectors, there was the matter of ordering them. One store might have the 4 mm bullets, but not the wire I wanted, etc.
So here I was, trying to consolidate my order and as I work down my list, I keep running into "out of stock". Now, I know that when ordering from the US suppliers, EP Buddy, RC Dude, etc., not to worry about shipping as it doesn't amount to much anyhow. Some stuff I wanted from Hobbyking, but that takes forever.
Soldering I can do, but everything else is a learning experience. Last nite, I spent several hours practicing how to install Andersons on thick[12 ga.?]silicone wire.
Yeah, I suppose I could "twist and tape", everything will be hidden anyhow, that it wouldn't be any big deal. But I thought that if I'm going to be cutting off the kit supplied connectors, that I might as well try and use some quality stuff and do it neatly. And that takes time for a Noobie, at least this one.

[Drunkskunk]

Cut them. No problems there. If you need longer wires later, solder on longer wires.

[neptronix]

motomech, you will eventually have a lot of stuff around. I suggest you start buying said stuff, then you can find yourself in my same situation . Heatshrink, flux, and solder are all you really need here.. all available at your local radio shack in the worst case scenario. You will end up building a stockpile over time if you really get into this.

I've ran out of 4mm bullets like 3 times now and finally learned that i need to keep a few packs of 10x lying around at all times.. but i also have 3 eBikes, possibly going on 4.. okay, yeah i AM abnormal, but remember i came on here knowing zilch, ordered up a 250w cell_man MXUS kit and lipos.. nearly crapped myself the first time i hooked it up when i saw that spark coming out of the battery connector

The best way to learn is to do ... yeah i've done a lot of doing.. but you can too! this isn't rocket surgery, you can definitely mess up and find your way back.

Nept.
You have at this for a while and have forgotten what it's like to be noob. And you have a bunch of "stuff" lying around
Even once I decided what connectors, there was the matter of ordering them. One store might have the 4 mm bullets, but not the wire I wanted, etc.
So here I was, trying to consolidate my order and as I work down my list, I keep running into "out of stock". Now, I know that when ordering from the US suppliers, EP Buddy, RC Dude, etc., not to worry about shipping as it doesn't amount to much anyhow. Some stuff I wanted from Hobbyking, but that takes forever.
Soldering I can do, but everything else is a learning experience. Last nite, I spent several hours practicing how to install Andersons on thick[12 ga.?]silicone wire.
Yeah, I suppose I could "twist and tape", everything will be hidden anyhow, that it wouldn't be any big deal. But I thought that if I'm going to be cutting off the kit supplied connectors, that I might as well try and use some quality stuff and do it neatly. And that takes time for a Noobie, at least this one.

[dogman]

Those that are doing it, I bet they are Virgo's. I never have, but being a virgo I've been tempted to shorten a few, especially throttle wires that tend to have some extra length. You can tidy up pretty nice just by making one big fold back, and then taping the three wires into a tight package. locate it where it can tuck along the frame in the most inconspicuous spot.

Battery wire or phase wires way too long should be shortened. But I never ran into any all that long. That's the wire with expensive copper in it, so they don't make those so long.

[Tench]

Those that are doing it, I bet they are Virgo's.

Spot on!! and glad i am the way i am! allthough i like to think it is by concious decission

Making the wires just the right length is all part of a clean neat build, you can always cut and solder with heat shrink sleeves if you dont want to source new connectors. A multi pack of assorted size and colour heat shrink is only a couple of quid.

Simon.

[Drunkskunk]

Not a Virgo here

I cut all mine short and resoldered them inside the controller so I wouldn't have to redo the connectors.

[MadRhino]

I'm not a Virgo either. I'm a Lion, thus didn't feel the need to discuss something so obvious, and just did it.

[amberwolf]

Hey I wanted to see if anybody was doing this. Once I find the final location of all aspects of my ebike, mainly the controller, I'd like to remove all the excess wire. Does anyone else do this? Right now I have the wires wrapped around the velcro straps for my frame bag. I think it'd make a much cleaner look to get rid of all the extra wire.

Once you are really sure you want to shorten the wires, and are ready to do it, let me know. We can work out a time you can come over here and I can help you cut and splice all the bundles together, either by installing connectors at the splice points, or by splicing and covering in heatshrink to protect them.

You would just need to get the heatshrink and/or connectors; I already have the tools needed to do it. If my hands aren't working right at the time I might have to just show you how to do it and then you actually do it, but it's not too hard to do.


The tough part is figuring out exactly how long you want the wires to be, and being *sure* that is how long you want them. Harder to add wire back in than take it out, but possible to do either way.

[nechaus]

you can buy super cheap 75 amp anderson style connectors from hk..
you dont need to solder, just crimp.