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Woodtroll
Explorer
Aug 23, 2019

Rewiring Trailer Brakes - How to Allow for Axle Movement?

Hello, folks,

I am planning to rewire my travel trailer axle brakes using a 12/2 commercial brake wire such as this:

https://www.nassaunationalcable.com/12-gauge-2-conductor-duplex-brake-cable.html

I'm going to run a separate wire from a junction at the front of the trailer to each hub. Two axles means four hubs, so there are eight flex points in the wire (frame and axle on each wire) that will be moving constantly. I know that stranded wire is much better at handling flexion, but what else can I do at the point where the wire leaves the trailer frame to help ensure that the wire won't eventually break? Are there any "best practices" that would apply to this installation?

Many thanks!
Regan

12 Replies

  • Make sure you use the appropriate shielded wire anchors spacing them frequently along the run. Use strap ties to hold groups of conductors together. Allow plenty of wire in the flex areas and secure each end using the appropriate connectors. Whenever the wire changes direction, place an anchor at the beginning and end of each radius. Do not bend the conductors sharply. When the conductors are subject to flying debris, heat, moisture, dirt protect them with an additional corrugated plastic shield. For examples of what to do and how to do it, just look under the hood of any trucks with factory wiring. You'll immediately notice the difference between that and when trunk monkeys have been at work. Do it like the factory to minimize future issues.

    Chum lee
  • I would place the junction close to the axles, less wire to run and if one short section fails it is easy to repair or replace. Eventually the wires will fail due to flexing and abuse from road debris, salt etc, regular inspection is the key.

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