Vintage Windmill and Wind Generator Forum

I need to make a few twisted wire braces for my Dempster tower. Not whole lengths , just two foot
sections that I can tie into the existing damaged ones. The big end loops are damaged and unusable.
Has any one made a simple jig to produce what I need?
I have one idea involving two heavy springs to keep the wire tight while turning with a crank . Don't need a lot of turns.
Fixed loop would be around a one inch rod and loose ends secured to what ever the crank is turning.
All thread rod could be used to fix the length and amount of tension.
Any other methods would be appreciated.
Thanks,
Joe

Joe , in the past I have used # 8 fince wire , measure how long between ends , double that , fold in helf , clamp loose end in a vice , grab the loose ends and twist , test several times,

Joe I have complete lengths of twisted wire braces from a Stover tower that I believe are almost the same as demster.

You also can buy a special bit that fits in a drill to twist fence wire !!

Dan are saying you could bring them to the fair? I only have to makeup short lengths. Was going to
wind them into the twists of the long end and then just secure with touch of a welding rod to keep
them from unravelling.
I think if you don't keep the wires taught when winding then they won't twist evenly. Kind of like it look
the same as the original.
Off hand I am not sure how many I need. Also they all the same length?

Sorry Joe but i won't be going to the trade Fair i wish I could !!

My plans are to go. Hotel booked. No guarantees some thing won't come up that will prevent me.
Going to drive by myself. About 1100 miles. Have 1 stop in Saskatchewan on the way down.

Stover twisted wires have a slightly smaller loop for the eccentric, as are the eccentrics smaller than Dempster. I have many Dempster tower wires of differring lengths. Joe, sounds like you are perfectly capable of twisting up what you need.

To answer your question, years ago there was a person who did make up a jig for twisting wires. Don't even think about asking where it is, or who it was. LOL

Joe, I have a few Dempster twisted wire tower braces. They are from the bottom 2 sections of a 60' widespread towet, so are quite long. If you need one or several, I can deliver at the Trade Fair.

Joe this is a sample I twisted , make them short for slices or long for complete braces .