Introduction
Twisting and braiding horsehair into cords and ropes to use as electrical wiring insulators has a long history. While newer synthetic materials have largely replaced horsehair today, understanding the traditional skill of processing and working this natural fiber can be rewarding. In this comprehensive guide, I’ll explain everything you need to know about twisting and braiding horsehair for electrical applications.
Obtaining Raw Horsehair
The first step is acquiring untreated horsehair fibers to work with. Here are some common sources to obtain raw horsehair:
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Horse groomers and farmers - Connect with local stables, groomers, and horse owners to collect hair brushed and combed from horses. Most are happy to provide free hair clippings.
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Slaughterhouses - Horsehair collected at slaughterhouses is a traditional large-scale source. Check regulations in your area.
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Online sellers - Many websites sell raw, unprocessed horsehair from various global sources. Search for "raw horsehair" to find online sellers.
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Your own horses - If you have horses, regularly grooming and collecting their shed hair yields a free hair source.
For electrical wiring uses, collect long-strand mane and tail hairs around 12 inches or longer. Shorter hairs won't twist into a cohesive cord.
Cleaning and Preparing the Horsehair
Before twisting or braiding, the raw horsehair must be cleaned and prepared:
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Wash - Soak and rinse the hairs in mild soap and cool water to remove dirt, grease, and debris. Avoid using very hot water.
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Dry - Allow the wet hair to air dry completely before attempting to work with it. Spread it loosely on a screen or mesh to speed drying.
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Comb and orient - Use a fine-toothed comb to remove tangles. Combing also helps orient the hair strands neatly in one direction.
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Trim ends - Use sharp scissors to trim any uneven or split ends from the individual hairs to create clean ends.
Proper cleaning and prepping results in smooth, untangled, oriented horsehair ready for twisting or braiding.
Twisting Horsehair Strands
A basic way to form prepared horsehair into a wiring cord is twisting together strands:
Twisting Process
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Take washed, dried, and combed strands around 12 inches long. More shorter strands can be used, but may be harder to twist evenly.
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Separate into bundles containing 10-25 individual hairs aligned together. More strands creates a thicker final twist.
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Tie one end tightly together to anchor. This becomes the starting point.
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At the open end, gently twist the bundle continuously between your thumb and fingers to integrate the hairs together into a tighter helical form. Apply even tension down the entire strand as you twist.
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Slowly work your way toward the tied end twisting continuously. The goal is evenly distributed twisting along the entire length.
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When you reach the tied end, knot it off or bind it to secure the twist.
Uses for Twisted Strands
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Multiple twisted strands can be further entwined together into thicker cords for insulating electrical wiring.
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Single twisted strands also work for arts, crafts, jewelry, and other decorative purposes instead of electrical uses.
Braiding Multiple Strands of Horsehair
A more complex technique is braiding multiple horsehair strands or cords together:
Braiding Process
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Prepare clean, combed, and trimmed horsehair strands at least 24 inches long. For ease, anchor one end of each strand to a fixed point.
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Gather the strands together neatly side-by-side. Be sure the ends are evenly aligned to each other.
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Begin basic three-strand braiding by crossing the left, middle, and right strands over each other repeatedly toward the anchored end.
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Work slowly and maintain even tightness. The strands will integrate into a solid braided cord.
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When you reach the end, tie it off securely.
Braided Cord Advantages
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Allows combining multiple strands into an organized, engineered structure.
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Braiding integrates the strands tightly together for strength and protection.
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The round, compact cord shape resists tangling.
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Braided horsehair makes a handsome decorative rope in addition to electrical uses.
Properties of Horsehair Electrical Cords
What makes horsehair useful for electrical wiring? Here are some key properties:
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Heat resistance - Horsehair can withstand wiring short circuit heat better than natural fibers like cotton.
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Strength - Braided and twisted horsehair cords are surprisingly strong thanks to the fibers' keratin protein.
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Flexibility - Horsehair cords remain flexible without cracking or breaking under bending and use.
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Insulation - The hollow medulla of each strand and air pockets in the structure provide good acoustic and electrical insulation.
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Moisture resistance - Oils in horsehair help it resist absorbing ambient moisture. This is vital for safe electrical work.
These natural properties make properly processed horsehair an effective insulator for electrical wiring, historically and today.
Conclusion
I hope this guide has provided you a comprehensive overview of harvesting, preparing, and twisting or braiding horsehair into cords suitable for insulating electrical wires. While newer artificial fibers have displaced natural horsehair commercially, understanding and practicing these traditional fiber skills can still be highly rewarding. With practice and care, you can produce durable horsehair cords to safely insulate and protect your own wiring projects.