WesBell Electronics
Wire and Cable Blog

Cable Assemblies by WesBell Electronics – ISO 9001 Certified

When looking for a wire and cable distributor look for a company that offers their customers some kind of additional services. This way you can look for a one stop shopping vendor for all of their wire and cable needs. Specifically look for ISO 9001 Certified vendors to ensure that you get the highest quality products and services. Some companies can now manufacture all different kinds of cable assemblies to meet a customer’s needs.

50’ Cable Assembly

50’ Cable AssemblyThese specific kinds of cable assemblies are manufactured in house for our customers.  What we do is, we remove the outer jacket, then remove the shielding, and stripe the lead wires.  Now we don’t just stop there we also tin dip the lead wires and solder a thermistor to the wires on one end.  Now the customers can change the specifics and let us know just what the length needs to be and the tolerance for each assembly.

Cat5e Cable Assembly

Cat5e Cable AssemblyThe specific kind of assembly we created was a molded Cat5e.  Now we do not do the molding here at WesBell, but our vendor will send us the cable coiled up with molded ends.  Our job then is to remove 2 inches of the outer rubber jacket, and pull apart the bonded pair conductors.  Customers can choose if they want or need heat shrink tubing added onto the conductors.

Electronic 3 Conductor Cable Assembly

Electronic 3 Conductor Cable AssemblyThe particular assembly done here used a General Cable.  This brand of cable has a PVC jacket that covers three PVC wires.  When creating this assembly for our customers we strip off both layers of PVC insulation off of the conductors.  Then the copper strands are crimped and then inserted into a plastic housing unit that will connect the customer’s application.  Most of the assemblies we manufacture are created to specifically meet each customer’s individual and unique application.

Custom Steel Braided Assembly

Custom Steel Braided AssemblyThis is a custom electronic cable assembly for the customer.  This cable had an additional stainless steel braid cover, and had six PVC wire conductors.  In order to create the assembly we had to remove the PVC jacket, the stainless braid and the PVC insulation around each individual conductor.  Next we were able to pull the shield to the side and twist it, then solder the copper strands to hold their form.  Then to make sure no wire was left exposed we added an adhesive lined piece of tubing to help with the transition from the steel braid to the PVC jacket.

Each one of the cable assemblies we create are to each customers specifications.  Being ISO 9001 certified guarantees our customers receive high quality work from us every time.  The assemblies we manufacture are created to meet each and every customer’s specifications.

Written by: WesBell Electronics
ISO 9001 Certified

Crimping Burndy® Compression Lugs to Flexible Cables

Crimping Burndy Compression Lugs to Flexible CablesCompression lugs and the crimping tools used to attach the two are very important to have a good connection. The welding cable needs to be cut to the right length first of all. Then it is important to make sure you are using the proper tools to attach the compression lug to the cable. There are machines that will do this but some people may prefer to crimp the lugs themselves. There are hand help tools that will let customers do this. It is also important to look at all the options for hand held crimping tools.

Cut Wire to Length

Wires can be cut in two ways, either by machine or by hand. Machines can cut the wire to length and strip the insulation off each end, which prepares it for crimping the lugs. If you are cutting wires by hand you need to make sure that you leave enough extra length so the wire can be stripped of its insulation and have the compression lug crimped on the end and still have the wire or cable be the correct length.

Buy Burndy® Lugs

The Burndy® compression lugs are made to last. The compression lugs come in either long or short barrel. Customers can also choose a lug with either one or two bolt holes. The long barrel lugs will give customers an added crimp onto the welding cable. Adding another crimp onto the cable gives the customers a more secure connection. If the welding machine you are attaching the cable too vibrates a lot and there is going to be excess tugging and pulling of the machine around the shop then look at a compression lug with two bolt holes. This will give customers a sturdier and longer lasting connection to the welding machine.

Crimping Tools

Hydraulic compression tools are commonly used to crimp lugs to welding cables.  The hydraulic crimping tools provide 6 tons of force when crimping the lugs onto the welding cable. It also has other features that allow it to crimp lugs that are in tight areas. Each Lug requires a certain tool and dye to compress the lug to the cable. There are a variety of different kinds of crimping tools that a customer can purchase. There are the mechanical, hydraulic, battery powered, or even remote power compression tools. Each one of these tools is different so make sure you have done your research on each to find which tool will be best for what you need to be done.

The Burndy® crimping tools work best when attaching a Burndy® compression lug onto a welding cable. This is because each different cable or lug will need a specific kind of tool to crimp both together. Make sure you look into all of your crimping tool options before purchasing one. You don’t want to end up with one that won’t get the job done right the first time.

**We ship electrical wire to Indianapolis IN in 2 days through UPS.

Written by: WesBell Electronics

Cut, Strip and Crimp Wire Assembly – WesBell

We started selling wire and cable products over 25 years ago and customers have been asking us to cut, strip or crimp wire since the day we opened. Aside from electrical installations, it seems almost obvious that a spool of wire is going to eventually be cut to a certain length for an application. So we started letting our customers know upfront that we’ll cut, strip, crimp, solder, twist and assemble their finished product.

Assembly Process

Cut, Strip and Crimp Wire AssemblyIn the picture to the left you’ll see UL1015 PVC wire cut to about 6 inches. It’s an 18 AWG flexible hookup wire used in electronics and appliances that you can buy on our website. The red insulated flag terminal is crimped with a hand tool piece by piece and set up to fit the customer’s application. The opposite end is semi-stripped, leaving the extra piece of insulation on the wire to stop the copper strands from fraying during the shipping process. If the insulation is removed completely before shipping the product we’ll typically “tin dip” the ends in solder to hold all of the copper strands together as one.


Due to the high volume of this particular part we decided to automate the process a bit more. We bought the red insulated terminals on a reel that feeds into a crimping press with a foot pedal crimping process. The assembler inserts the wire into the terminal, presses the foot pedal for a secure connection and the crimping press automatically slides the next terminal into position. The process is about 4-5 times faster than crimping by hand, but much more expensive.


WesBell completes “in-process” quality checks after each part of the process is complete, along with a final inspection of the entire assembly. For instance, once the wire is cut and stripped on the wire cutting machine, 5% of the pieces are measured for accurate lengths. If one or more pieces do not meet the tolerance specified another lot will need to be measured and so on. Otherwise, if everything matches the data sheet, the parts move to the next step in the process.

Written by: WesBell Electronics
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Wire Assembly Using UL1015 Hookup Wire

WesBell Electronics is a mature ISO9001 certified company that manufactures wire assemblies, harnesses and kits to our customer’s specifications. We no longer need to tell our customers about our quality of product because our ISO certificate proves it. We’re audited on a quarterly basis along with a more in-depth audit annually to confirm that our processes and procedures meet the standard.

Hookup Wire

UL1015 12 AWG Wire AssemblyThis wire assembly is comprised of three 12 AWG wires that are each approved by UL under the UL1015, UL1011, UL1230 and UL1335 categories. UL, Underwriter’s Laboratories, uses each UL designation to show what the wire has been tested to withstand. For instance, UL1015 wire is approved to resist moisture, withstand up to 600 volts and withstand up to 105°C in any given application. These PVC wires were manufactured to be used in electronic devices and appliances as long as they meet the criteria of the UL standard. See our UL1015 12 AWG wire here >>

Cutting Machine

WesBell Electronics has many wire cutting machines that we use to cut large quantities of hook up wire for the biggest companies in the world, including GE. We do not resell our wire cutting machines, we use them for high volume production. In this case, the machine was set to cut the wires to about 12 inches long and semi-strip each end. The slugs remain on the end of the wires so that the copper strands won’t get damaged of frayed when shipped. Our customers set the length and tolerance of each job.

Tie Wraps

Once each of the three wires are cut, measured and checked for accurate lengths, we bundle three wires together and tighten a tie wrap around them. Due to the high volume of production, we also have a tie wrap cutting tool that tightens the tie wrap and cuts the excess plastic for a clean finished product.

Instead of creating our brand name wire harnesses and attempting to find customers that purchase them, we let our customers inform us of exactly what they need. Some jobs are quick and simple while others are much more complicated. More complicated wire assemblies will sometimes require engineering, specification data sheets, sample prototypes, customer visits and months of production. We have a strong online presence and require positive feedback in order to remain a strong player in the wire harness and assembly industry. Feel free to browse around online to find comments and testimonials about our company.

See us here: WesBell BBB | WesBell eBay

How Can WesBell Improve 100% Positive Feedback from 2014?

100% Positive Feedback from 2014
In 2015 we plan to be focused on our customers, our website and our value added services. Although, how do we improve 100% positive feedback? Well, over the past 13 years we’ve maintained a perfect feedback rating from our eBay customers, but we received a few complaints from our website customers. We aim for perfection each and every time, but we also understand that things will go wrong when we’re busy. Therefore, we like to pay special attention to those customers that experienced a problem when we processed their order. In other words, we don’t mess up that often, but when we do, we make it up to you. That’s our guarantee. Humans can’t guarantee perfection but they can guarantee to “make it right.”

Value Added Services

We’re an ISO 9001 certified company that manufactures wire harnesses and cable assemblies upon request. Roughly 80% of our sales are generated through bulk wire and cable orders, however we’re focused on increasing our production department in order to service more customers in a faster period of time. Quick delivery times continue to be a top priority for our customers that manufacture electronic devices and build electrical enclosures.

We help our customers with this issue by keeping a buffer quantity on the shelf at all times. If our customer typically buys 1000 pcs per month, we’ll have about 200 pcs on the shelf at any given time in case they need a quick delivery. We also work on our relationship to better understand the main concerns of each unique customer and better serve them each in their particular way.


We plan to increase the functionality of our website in 2015 without changing the layout or design. We want to create a better user experience, not just on desktop computers, but also on mobile phones. Within about 6 months we plan to set up customer profiles that allow customers to save their information and easily purchase items listed in their history. Our customers on Net30 terms will also experience increased functionality because they will be able to log in and view open invoices, along with placing new orders without waiting for an email to get processed by a real person.


Consumers are getting smarter, purchasing departments are getting smarter, and demands are getting more specific with the help of technology. When customers like General Electric request to have product on a specific day, they need it on that day because they have a production line ready to use it. Individuals are different than companies, but individuals also plan to use incoming shipments as soon as possible. The fact of the matter is, we commit and deliver. If we aren’t going to meet a date provided by a customer we’ll call them ahead of time so that they can plan accordingly.

The only thing worse than messing up as a vendor is not admitting when you’re wrong. I can’t say that WesBell has never messed up an order, but I can say that we’ve corrected every wrong that’s come about. I believe that’s why we have high positive feedback from our customers. We treat them how we want to be treated!

Written by: WesBell Electronics Inc

Top 3 Safety Tips for Welding Wire and Other Materials

Anyone familiar with welding knows that welding accidents aren’t pretty and should be avoided at all costs. As the practice of using heat and flux to fuse together two pieces of metal, welding is a dangerous activity, even for seasoned pros. MIG welding in particular is susceptible to accidental injuries and damage around the workplace. But how can you prevent accidents from happening? That is what we’ll be discussing in this article.

  • Protect Yourself

Welding produces sparks and high intensities of both light and heat. One of the first lessons that every welder learns is that they should wear a full face mask when using an arc welder in order to prevent the corneas of their eyes from getting damaged.

With MIG welding, however, there is an additional danger to the welder that needs to be addressed. MIG welding produces light that contains strong UV rays. These rays can burn and blister the skin unless the welder wears gloves and covers as much of their body as possible with clothing. This precaution also helps prevent burns from flying molten metals that are produced during welding wire together.

  • Protect Your Work Area

It’s important to fireproof an area as much as possible when MIG welding. Keeping the area free of plastic, paper, sawdust, and other highly flammable workshop materials is essential to the safety of all workers and welders that are using the space. Additionally, keeping a fire extinguisher nearby is always a smart move while welding.

  • Protect Others

When it comes to MIG welding, it’s important to focus on the safety of everyone involved. Welding wire gives off ozone and some alloys can even release fumes that lead to severe metal poisoning. Whether you’re working alone or with others, it’s essential to have a well-ventilated space in order to work.

Even though these tips might seem fairly obvious, it’s easy to overlook simple things because of impatience. Always make sure that someone who is familiar with the process is there and that the project is thoroughly planned out before welding in order to avoid common safety hazards.


Three Types of Electrical Wire: THHN, UFB, and Romex Wire Revealed

There are many types of electrical wire available for consumers, however, it’s easy to get confused by the different types. The most common types of electrical wire are THHN, Romex, and UFB wire. However, in order to understand which electrical wire will do the best job for a specific project, it’s best to know the capabilities of each kind of wire.

  • THHN Wire

THHN wire is covered with a PVC jacket and nylon coating. This wire is a bare one conductor copper wire and is often used indoors or in conduit. The most popular sizes for THHN wire are 12 and 4/0, though other sizes are available for nonstandard projects. The PVC jacket is one of the cheapest forms of insulation for this type of wire and the nylon coating provides waterproofing and slight lubrication for placing in a conduit. Because of the ‘bare essential’ nature of this wire however, it isn’t recommended for outside use.

  • Romex Wire

Romex wire is made out of two or three THHN wires combined with a grounding bare copper wire. Like the THHN wires, Romex wire can’t be used outside because of its minimal PVC jacket protection. However, these wires come in larger sizes than the thinner THHN wires; 14/2 and 6/3 are used widely as electrical wire, despite the fact that it can’t be used in conduit at all. The primary use for this type of wire is to run more than one conductor at a time through a separate grounding wire.

  • UFB Wire

UFB wire is one of the most popular and versatile brands of wire available, though it’s also the most expensive. It can be used in conduit, outdoors, underground, you name it. Because it deals with tougher terrains than THHN or Romex, UFB wire comes in larger sizes, most commonly 6/3 and 8/3 and is often called ‘underground cable’.

The more jobs that an electrical wire does, the more expensive it is. It’s important to know what the different electrical wires do before committing. Frequently, that added expense can save a lot of costly replacements and time-consuming repairs.


Power Cable Accessories: 3 Things to Know Before You Buy

Power cable accessories are important tools that help to distribute power among devices in a safe and effective manner. However, because of the wide variety of these accessories, it can often be confusing to know which one is the one you need. When purchasing accessories, consider these three things, quality, location, and specifications.


  • Quality- Getting The Right Accessory

Each company that develops power cable accessories have their own strengths and weaknesses. This means that, despite having two similar products, one brand might be more suitable than another for a certain project. An easy way to determine what type of accessory you need is to find out which accessories are meant to be used in certain environments and what the different amounts of electrical current they carry. From there, a sales associate can assist you in fine-tuning your search more effectively and let you know which brand is the best for your needs.

  • Location- Where Will It Be Used?

So many people overlook location when they’re deciding on what type of power accessory to get. This is a major mistake! Location is one of the most important questions to ask yourself about before you purchase because everything else depends on it. For example, outdoor use cables will be more flexible and made from hardy materials that can withstand wear and tear from outside environs and situations.

  • Specifications- Wattage Rating And Other Concerns

All electrical cables and cords have small metal wires that are meant to conduct electrical currents. The thickness of the wire will let you know how much current, or wattage, a certain wire can carry. The wattage rating is the amount of wattage that a wire can safely handle. It’s recommended that you know this important number before you use power accessories, particularly if you’re powering multiple devices from one source.

Most of the information that you’ll need can be found on the labels and product specs of a particular accessory. However, if you’re uncertain or don’t understand, it’s always a good idea to ask for help from someone who is knowledgeable about the various products.


Insulation Matters: The Differences between 4 Common Hook Up Wires

PVC hook up wire requires different levels of insulation in order to fully protect itself from corrosion. Corrosion can occur from a number of outside elements, from the environment that the wire is in to temperatures and accidents. In this article, four different types of wires and insulation will be discussed namely, UL1007, UL1061, UL1015, PTFE Teflon wire.

  • UL1007 Wire

UL1007 is meant to be used for projects that require 300 volts. It has .016” insulation thickness and has been certified by Underwriters Laboratories, or UL, for temperature and voltage reliability. However, despite being certified by UL, the high voltage of this form of wire usually requires third party approval for use by commercial properties.

  • UL1061 Wire

The UL1061 is very similar to the UL1007 because it has the same amount of voltage at 300 volts. However, the primary difference between these two is that the UL1061 has .009” insulation thickness. Its slimness makes this hook up wire ideal for work that requires the same kind of punch as the UL1007 while needing a smaller outer diameter.

  • UL1015 Wire

UL1015 wire has double the amount of voltage as the UL1007 and 1061. Thanks to its 600 volts, it also requires a lot more insulation to keep it protected. Because of this, UL1015 requires .032” of insulation, almost triple that of the UL1061! Like many types of wire, UL1015 can handle temperatures up to 105 degrees Celsius.

  • PTFE Teflon Wire

PTFE Teflon wire is high-grade wire that can withstand temperatures of 200 degrees Celsius- almost double of what the UL wires can. Because of the high temperatures that this wire is often submitted to, PTFE uses silver plated copper strands instead of tinned copper. Also, PTFE has a nonstick surface which protects the wires from water, oil, solvents, and even gasses.

There are many different kinds of wire available and each one has its own specifications, insulation, and capabilities. Having the right information is crucial and so it’s always recommended to talk to a sales associate who is knowledgeable about the different kinds of wires before buying.


Finding the Right Electrical Cable for Nearly Any Project

Electrical cables come in a variety of forms, all of which have their own unique uses and capabilities. But what kind of cable is ideal for each job? When choosing the ideal cable for a particular project, there are endless possibilities! In this article, however, there are three different types of cable that are going to be explored: low-voltage, optical fiber, and coaxial cables.

  • Low-Voltage Cable

Low voltage cables are usually created from plain flexible copper conductors that are bunched together. These cables are insulated and colored so they’re safe to use and easy to identify. The copper core wires are twisted together and then covered with a flexible form of high grade PVC, or polyvinyl chloride. These cables are used for a variety of products, from everyday appliances to small industrial machines.

  • Optical Fiber Cable

Optical fiber cables are great for electronic devices that need to carry and transport data. These cables are fairly common and are used in households and data centers around the world. Televisions, internet, and other complex electrical equipment use these wires and most people are already familiar with how they work. Optical fiber cables are also some of the most reliable forms of cable, thanks to their flexibility and efficiency.

  • Coaxial Cable

Coaxial cable is another commonly used electrical cable. This cable has an inner conductor which is surrounded by insulation. It connects with other devices used a tube-like conducting shield. The coaxial cable gets its name because both conductors run parallel to each other on the same axis. Many households and commercial businesses use this form of cable, however, its most common usage is to connect a TV to an antennae.

Understanding what each type of cable does best is a great way to decrease the uncertainty of an electrical project, particularly if you’re doing it yourself. Also remember that electrical accessories are available which can make a potentially frustrating project even easier. If you’re uncertain about what type of cable or accessory is needed for your project, it’s best to ask a trusted and reputable expert to assist you.