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Wire wraping Bose 802 drivers


parky58

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I have a troublesome bose 802 Mk1 which has a hard to find "rattle", having re-foamed or re-coned all the drivers as they were in poor condition and as a last resort I have completley stripped the cabinet (where I found several foreign bodies lurking). I would now like to re-wire, using the wire wrapping technique if possible. Can anyone recommend an appropriate tool and wire?
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I haven't seen a wire wrapping tool for very many years - they were widely used for mass termination of wires in telephone exchanges back in the 70's and 80's and I suspect that if you could find one to purchase new - you wouldn't want to pay the price!

 

There is absolutely no problem with hand wrapping normal stranded tinned copper wire around the post - then soldering.......

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Don't bother; it'll not be successful.

 

To work properly a wire-wrap joint needs to make a gas-tight seal/cold-weld on the corners where the wire wraps around the posts. To do this you need to use the right tool with the right wire and have it set to the right tension. And be skilled at doing it.

 

I have a tool here for doing circuit board wire-wrapping. It cost over £500 and that was 15 years ago. The bits for it wear out. The last ones I bough were £120 each and that was 10 years ago.

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Don't bother; it'll not be successful.

 

To work properly a wire-wrap joint needs to make a gas-tight seal/cold-weld on the corners where the wire wraps around the posts. To do this you need to use the right tool with the right wire and have it set to the right tension. And be skilled at doing it.

 

I have a tool here for doing circuit board wire-wrapping. It cost over £500 and that was 15 years ago. The bits for it wear out. The last ones I bough were £120 each and that was 10 years ago.

 

While none of the above is wrong, it is perfectly possible to do this by hand using the right tool - which is still available and doesn't cost very much - Farnell stock many of them, example here. As Brian mentioned, you'll need to make sure you use the correct wire - with a little bit of practice, you can produce joints every bit as good as those produced using a machine. I used to use exactly this method to design and prototype embedded computers in the past.

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Indeed. Back at university I wire-wrapped a complete ISA computer interface card (kids, ask your parents). I hate to think how many connections there were - you could barely see parts of the board for all the wires - but we were told at the time that it's more reliable than soldering as it's essentially a cold weld. I certainly wouldn't argue with that.

I still have the tool and some reels of cable somewhere - it wasn't expensive.

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Remember - the OP is looking to wrap speaker sized wire not the stuff we use to wrap circuit boards.

 

The link to Farnell shows the largest tool they do handles just 22 AWG wire onto 1.0mm x 1.0mm pins. I'd not want to rewire 802s in 22AWG.

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Thanks chaps. On examination the speaker posts are 0.8X1.6mm and the wire is 0.8mm, therefore the farnell tools wouldn't do the job. I think for the sake of one old MK1 802, the cost of tooling up would be prohibitive. I do like where possible to use original components and methods. I have found that soldering onto these posts is sometimes difficult (they appear to be made of steel), with the solder not taking properly. I am also wary of using excessive heat and melting the surround. I think I will proceed by wrapping stranded wire and soldering - carefully!
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