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TR2/3/3A TR-3 Control Head - Threading the Needle

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dspeed

Freshman Member
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So I sprang for a new control head; now I'm trying to get the wire down the tube. My tube was broken right at the end of the slit on the top. I have welded it successfully, but I fear I have added just a tad of roughness on the inside (and, yes, I did try to smooth it out before I started).

The first attempt stalled about 10 inches short of success ( despite flushing w solvent and running a rod through this w a plug of rag at the end, the wires scraped put some noticable amount of crud).

But now, the coating on the wires isn't stiff at the end anymore and the cover is bunching up big time. What can I do to replace the coating?

Dave
 
I remember getting a new control head and running the wires out the end of the tube. I still have nightmares from that adventure. If I recall correctly, I staggered the terminals on the ends of the wires, then wrapped them (tightly)in electrical tape. I may also have run some thin wire (light gauge picture hanging wire)under the electrical tape and out ahead of the terminals so that came out first. I could then use a pulling/pushing action to get the wires through.

I don't remember any "coating" on the control head wires other than normal insulation. Maybe they've changed the design.

If absolutely necessary, new tubing (pipe) can be purchased and cut to length.
 
run a piece of heavy string or a single wire through the tube. Then tape it to the end of the control head harness being careful not to make the tape bigger around than the tube. Then feed the wires in and do a push- pull dance.
I also find that rotating the wires in one direction as you thread them tends to make them wind togeather tighter and fit easier.
If the sheathing is bunching up on the end, try giving it a tight wrap or two of electrical tape.
 
As noted, pulling is definitely better than pushing. If you still have the bullet connectors installed and find that staggering them doesn't produce a compact enough bundle, just remove them and put them back on when the wires are through.
 
I have unsoldered one bullet (the lead) and soldered a pull wire onto the harness, but I am experiencing difficulty with the black cloth sheath bunching up as it hits the (very slightly) rough spot where the repair was made.

I've tried electrical tape and find it just slides back.

I think I'm down to binding the end of it with thread and hainting it w some enamel paint to dry straight and hard.
 
FOLLOWUP: TR-3 Control Head - Threading the Needle

Success!

I trimmed off approx 4" of munged up stuff and started over.

Soldered in a lead (pull) wire. Dressed the welded pipe internally w a file. Pulled down the cotton sheath , tied w heavy thread and painted w black enamel paint for approx 2". I let this dry and lightly coated the black sheath w a bar of Ivory soap.

I should have paid more attention to the sheath before i started (and again before my restart...). There were 'wrinkles in the sheath that i should have worked out by pulling from the control head end to reduce. After getting by these, we were successful.
 
Re: FOLLOWUP: TR-3 Control Head - Threading the Needle

good tip with the soap. I woulden't have thought of that. Even though I use it for other things.
 
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