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AFEngine wiring harness – the twisting process
We often see comments saying that this type of harness twisting significantly increases wire length. So we decided to make a small report.
Length of this twisted section: 50 cm
Number of wires: 46 (not including the shielded wires, which are placed in the center and do not change in length).
Each wire from the outer layer became shorter by about 2.5 cm on average due to the twisting process.
Let’s calculate the wire consumption:
46 × 2.5 cm = 115 cm
So we “lost” just a little over 1 meter of wire due to the twisting.
Conclusion:
Wires are always cut from the spool with a 15–20 cm margin. About 3 cm of that goes into the twisting itself. The remaining margin is simply a guarantee that the wire will reach from point A to point B without ending up too short, and very often this extra length just gets trimmed at the final stage.
So what do we lose because of twisting?
A couple of centimeters of wire.
What do we gain?
A strong, flexible, and uniform harness that is easy to route inside the car. No wire remains under tension because the load is evenly distributed thanks to the twisting.
This method is used not only in the military industry but also in everyday applications: textile ropes, the steel cable in your bicycle, high-voltage power transmission lines, and bridge support cables all use similar principles.
Thanks for watching!
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