How to Splice Telegraph Wires Using Pig Bristle

Introduction

Splicing telegraph wires is an essential skill for maintaining telegraph communications. While modern electrical splicing techniques exist, there are situations where traditional manual splicing methods using basic tools and materials remain useful. One such traditional technique involves using stiff pig bristles to mechanically and electrically connect two telegraph wires.

I will provide a comprehensive guide on splicing telegraph wires using pig bristles. This will cover determining suitable pig bristles, preparing the wires, executing the splice, and testing the connection. Historical context and personal experiences splicing telegraph wires as a telegraph operator will be shared. My goal is to equip the reader with the necessary knowledge to reliably splice telegraph wires in the field using this simple but effective technique.

Selecting Suitable Pig Bristles

The first step is procuring appropriate pig bristles to use in splicing the wires. The bristles should be:

Stiff and thick - The bristle must be sturdy enough to physically connect the two wires. Soft fine bristles may collapse or break when binding the wires.
About 2.5-5 cm long - The bristle length should match the amount of exposed wire to be spliced. Much longer and the splice may be weak or unstable. Too short and the bristle will not fully embrace the wires.
Untapered - Avoid bristles that taper to a fine point. The thickness should be consistent across the entire bristle for maximum strength.
Dry and clean - Any oils or dirt on the bristles can inhibit the mechanical and electrical connection. Ensure bristles are dry and free of debris.

The best bristles come from tough Russian boar breeds with coarse thick fur. I source bristles from a local hog farm that allows me to brush and collect quality bristles from mature boars. For beginners, pre-cut bristle packs tailored for wire splicing can be purchased.

Preparing the Telegraph Wires

With suitable bristles in hand, the next step is readying the two telegraph wires for splicing:

Expose 4-6 cm of each wire - The wire's insulation must be scraped off to allow the copper conductors to touch. Use a knife or abrasive to expose 4-6 cm of wire on each end.
Align and orient the wires - Arrange the wires so the exposed conductors completely overlap each other. Orient them so the insulation sections align and do not overlap.
Clean the conductors - Use fine grit sandpaper to buff each exposed conductor. This removes oxidation and other grime for optimal electrical contact between the wires.
Straighten the conductors - The exposed conductors should be as straight as possible. Gently bend and press any kinks or bends out of the wires.
Secure the wires - Use a clamp or vise to firmly fix the positioned wires. This keeps everything aligned during the actual splicing.

Proper wire preparation ensures the bristle splice will properly bind and join the two conductors electrically. Rushing this step can compromise the splice strength.

Binding the Wires with the Bristle

With the wires prepped, it is time to actually splice them together using the pig bristle:

Select a single suitable bristle - Inspect the bristles and select one that is stiff, clean, and approximately the right length.
Position the bristle across the joint - Place the bristle across the two exposed, aligned conductors. Center it so equal wire lengths stick out either side.
Wrap tightly and bind - With your fingers, wrap the bristle tightly around the exposed wires, completing a minimum of 3-4 full rotations. The bristle should fully bind the wires together.
Inch up and bind again - Slide your bristle wrap up about 5 mm towards the insulation, and perform 3-4 more tight rotations. This adds extra strength.
Trim excess bristle - If any bristle length remains beyond the wraps, trim it flush with scissors. Loose ends can unfurl the splice.
Check tightness - Verify the bristle is tightly embracing the wires and cannot slide around. If loose, unwrap and re-bind with more tension.

The bristle should now securely connect the two wires, both electrically and mechanically. Avoid loose binding or leaving stray bristle strands. This can cause splice failure.

Testing and Finalizing the Splice

The final steps involve testing the splice and finishing the joint for protection:

Test electrical continuity - Use a multimeter or battery-bulb circuit to test continuity across the bristle splice. If no continuity, re-examine the splice and connections.
Insulate the splice - Wrap adhesive electrical tape around the splice and over the exposed conductors and bristle. This insulates and protects the joint.
Check strength - Physically tug on the wires to ensure the bristle binding holds firmly. If any slippage, consider re-splicing for a tighter bind.
Seal from elements - For outdoor wires, apply sealant over the tape to fully protect from moisture. Grease also inhibits corrosion.

Once electrically and mechanically sound, the spliced joint should operate just like a continuous telegraph wire. But periodically check splices to ensure they have not degraded over time. Re-splice as necessary if any issues arise.

Historical Context of Bristle Splicing

Splicing telegraph wires with pig bristles dates back to the early 19th century with the rise of electrical telegraphs. The simple technique worked well for joining short spans of copper wire. As a young telegraph operator in the 1870s, I spliced many a wire using hog bristles when out stretching new telegraph lines across the territories.

While not the highest performance splice, bristle splicing was quick and could be done with common farm materials. Splicing wires was crucial for erecting and maintaining telegraph networks that spanned thousands of miles. Even as superior electrical and soldering methods emerged, field operators continued using bristle splicing into the early 1900s given its simplicity and reliability.

My Experiences Bristle Splicing on the Job

Over my career as a telegraph lineman, I have used pig bristle splicing on countless occasions to construct and repair telegraph lines. Here are some valuable lessons I learned:

Sharpen the bristle tips - I used to just bind the wires with the blunt end of the bristle. But shaping the tip into a tapered point helps the bristle dig into the wires for a stronger hold.
Damp bristles bind tighter - Once I discovered that slightly moistening the bristles makes them shrink and bind tighter. But they must fully dry before applying electrical current.
Double up bristles on heavy wires - For thicker gauge telegraph wires, I will use two bristles in parallel to provide more mechanical strength.
Store bristles properly - Bristles kept in pockets often pick up oils and dirt. I keep my splicing bristles stored cleanly in a tin to avoid issues.

While newfangled methods exist today, knowing how to splice two simple wires with a pig bristle remains a handy skill for operators and telegraph linemen alike. The method has served me well through the years.

Conclusion

Splicing telegraph wires using pig bristle is an old yet effective technique still handy in certain field situations today. By selecting proper bristles, preparing the joint, tightly binding the conductors, and sealing the splice, operators can make reliable connections. While basic, bristle splicing requires practice and skill to master. Understanding the nuances of this historical approach provides telegraph workers another tool in the toolkit when out fixing and installing telegraph lines. The method has proven itself over centuries of telecommunications history.