Tam Valley servos: mounting and bending the piano wire

[videobruce]

I'm trying to figure out how to consistently bend the piano wire to the exact length to fit the 'horn' openings. WE are talking about to + or - .1mm
Other than it being impossible to do it correct once how can you make the exact same 'U' dozens of times without re-bending the wire until it breaks??

I have the 'Singlet' decoder as a trial package along with the mounting bracket from Motrak as a test/trial piece. I plan on using numerous 'Octopus' controllers as opposed to single controllers due to the obvious; cost and size/space considerations.

The only thing I can figure is some 'form' that the wire can bent around in a 'U' instead of two right angles. That way with a gentle 'bend', tweaking the spacing would be easier.

This shows the situation making it look easy;
http://www.tamvalleydepot.com/support/servomounting.html

 

[waltr]

Yep, make a 'form' to bend the wire around. Since you are bending piano wire, which is hardened, the form should be steel.
What is the dimension of the inside of the 'U' bend?
Find a piece of steel that is just smaller that this dimension. Look around as you can use many odd things like shelve brackets, L brackets or anything else of that thickness.
Mount the steel piece in a vice to make it easier to work with.

Another totally different way is using a pair of needle nose pliers. Find where in the pliers jaw that has the width required and either mark that spot so you can place the wire there repeatedly of even grind a small groove across the pliers's jaw to hold the wire.

The rounded "U" shape should also work and would allow a bit more tolerance in the bends.

 

[videobruce]

There are 5 holes in the 'horn' that was used (out of 4 supplied), 2mm between holes. Using three would make the distance 6mm.

The rounded "U" shape should also work and would allow a bit more tolerance in the bends.

This seems to make the most sense as opposed to the pics I have seen with right angles bends.

As usual, nothing is mentioned on how to do any of this.

 

[Old 97]

Build a wire jig:

http://jewelrymaking.about.com/od/wirejigpatternsprojects/a/081907.htm

 

[Big Windy]

You can make a device out of steel. Drill a hole the size of the wire. Drill to the depth you want to bend.use the shape of the steel as a template. Round stock, square etc..

 

[videobruce]

Someone else suggested dropping the wire in from the top through the throw-rod that has a 'hook' it doesn't just drop through. No bend at the servo.