While working on my Crosley tube radio recap, I've come across several wires where the insulation is very brittle. Flexing the wire causes the insulation to break off, usually where the wire has been bent or close to a hot spot.

My question is how much of this to tolerate? Should I replace all wires that are suspect, or just those where the insulation is actually cracked or broken and try to get away with the rest? What about just covering them with shrink wrap?

My gut feeling is simply to replace anything I don't trust.

Trust your gut.

Trust your gut.

Yep, don't take short cuts. My Brother In Law tried to insulate the bad wires on a very nice 40's Zenith Console. He now has a display radio because the p/t. opt and a lot of components are fried:thumbsdn:

Some people will disconnect one end of the wire and slip heat shrink tubing over it. I think that looks horrible and would not do it. But it is an option. The best thing to do is to disconnect one end of the wire, tack solder a new wire to it and use the old wire to pull the new wire into place. That way, your wire routing is in the same place. It will help avoid needing to do an alignment.

You can use all one color wire. But matching the wire may make it easier. Radio Daze sells wire. You don't have to use cloth covered but it looks better!

Yeah do it right the first time. I'd get cloth wire if that is what is there now. Tube depot has some that I got for a project once. Is nice silver plated copper with many colors available. http://www.tubedepot.com/wire.html
John

I replace all that crumbling wire on all my consoles. It takes a while, but it's a safe radio now.
Radiodaze is the least expensive I've found for cloth covered wire, and they're really nice to deal with:http://www.radiodaze.com/wire-cloth_covered.htm
I used it to build my KT88 SE amplifier, looks really nice!

i replace what has crumbled and what may pose a hazard. that wire has taken shape. if not disturbed it can sometimes be left alone. its a big judgement call on your part.

oh, rubber wire. I removed every inch of that stuff from my '39 Philco and replaced it with new wires, piece by piece. It took a while but now I'm not afraid to use the thing.

You didn't mention whether or not the original wire was cloth insulated or rubber insulated, but I'm guessing rubber.

You need to replace it all. Might as well get started. It'll be done sooner that way.:yes:

Wow, thanks for the response. I thought it was a stupid question, but I'm happy for all the good advice, especially the tip about how to thread the new wire in. I think most of the wire insulation is rubber, the wire with the crumbling insulation is solid, but there is also stranded wire and some cloth-covered wire. I was just going to use modern wire, but if the cloth-covered stuff isn't too expensive, I might invest in a roll. I ordered the caps today from justradio, but they don't sell wire. :no:

http://www.audiokarma.org/forums/attachment.php?attachmentid=149390&d=1241754743

And thanks again to everyone.

Rubber. You can get different colors, afaik.

[QUOTE=StarMover;2743065]Wow, thanks for the response. I thought it was a stupid question, but I'm happy for all the good advice, especially the tip about how to thread the new wire in. I think most of the wire insulation is rubber, the wire with the crumbling insulation is solid, but there is also stranded wire and some cloth-covered wire. I was just going to use modern wire, but if the cloth-covered stuff isn't too expensive, I might invest in a roll. I ordered the caps today from justradio, but they don't sell wire. :no:

Hi,
Check out www.tubesandmore.com They had original looking cloth covered wire for old radios. Using that type of wire would allow you to retain that classic look of the circuitry. I would replace only the wires that had the issue. Many do not run near hot resistors and such and are most probably fine and better off left alone. Do only one wire at a time! it is easy to get lost in the jumble of wires in these old sets and make a mistake.