How To Assemble An Electric Foil

The following discussion explains the process of constructing an electric foil. If you are building a dry foil you may skip the parts that discuss wiring.

The following instructions assume that you have a wired blade. For instructions on wiring foil blades click here.

For the purpose of this description, the side of the blade with the wire groove will be designated the top.

Step #1

  • Thread the end of the wire protruding from the blade near the tang through the insulating sleeve commonly referred to as spaghetti. This is a deceptively difficult procedure if (as is most often the case) your wire is insulated with cloth. First you should cleanly cut off the very end of the wire so that the insulation is not frayed. When you start to apply the spaghetti try twisting it counterclockwise* and continue this motion throughout the procedure. This has the effect of preventing the insulation from fraying.
  • Make sure that the spaghetti fits snugly against the blade. Many blades have an expanded groove near the tang who's purpose is to hold the spaghetti. This is a good idea but most of these grooves are longer than necessary. If your blade has one, then use it; but try to use only the very end of the groove.

  • Step #2

  • Chances are that the end of your wire extends far beyond the end of your spaghetti. If so you should crop it to a more reasonable length but don't make it too short.
  • The length of wire that protrudes from the spaghetti should be stripped. You can do this latter, but it's easier now. If your wire has cloth insulation you should use a piece of emery cloth. This is the easiest way and will also remove any lacquer that may reside on the surface of the wire itself. If your wire has plastic insulation then you can still use emery cloth but I prefer to use a small pair of sharp nosed diagonal cutters. This takes some practice, however, so be very careful not to cut the wire by accident.

  • Step #3

  • Make certain that your bell guard has an adequate groove for the insulated wire to pass through. If it doesn't then you will need to enlarge it with a file or other tool.
  • Put the bell guard on the tang threading the wire through as you go. Make sure that the groove in your bell is aligned with the groove in you blade. Be careful not to break, kink or scrunch the wire in the process. also, beware of damaging the spaghetti.

  • Step #4

  • Repeat step #3 with your guard socket
  • If you have a French style 2-prong socket, look at the underside. One of the screws has two nuts while the other has only one. loosen the first nut on the screw with two. Wrap the wire loosely around the screw between the two nuts.
  • Tighten the nut down being very careful not to to catch the wire in the threads. If you're not careful you can easily break the wire.
  • If you have a German style 2-prong socket, loosen the screw with the smaller hole through it.
  • Thread the wire through the small hole in the bracket and wrap it loosely around the screw.
  • Tighten the screw being very careful not to to catch the wire in the threads. If you're not careful you can easily break the wire.
  • If you have a bayonet socket, loosen the small screw on the side of it and wrap the wire loosely around it.
  • Tighten the screw down.

  • Step #5

  • Put the thumb pad on the tang

  • Step #6

  • Make sure that your pommel has the same thread as your blade
  • Check to see if your grip has an adequate groove for the wire. If it dose not then you must make one with a file, grinder or other tool.
  • If you have a French grip, put it on the tang being sure to align it with the grooves in your bell and blade. You must also look under the thumb pad to confirm that your wire is lined up correctly with the groove. If it's not, tightening the handle will break it!
  • If you have a pistol grip, insert the lock washer in its chamber and put the handle on the tang. Make sure that the washer winds up on the tang, not along side of it. Align the groove on you handle with those on your bell and blade. Look under the thumb pad and confirm that your wire is lined up correctly with the groove. If it's not, it will break when you tighten the handle.
  • While putting on your pommel, gently thread it backwards first to ensure correct thread alignment.
  • As you tighten the pommel be sure that you don't accidentally twist the handle because you could break the wire. This is easier if you use a vice to hold the blade.

  • That's it, you're done!

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