Heated Gear - Homemade

hemibee

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From a friend of mine, I have not tried this and have no first hand knowledge but he is in to Iron Butts and other distance rides in all weather conditions and uses this gear, giving it a good test.

I've been making (and refining) and wearing my own heated gear for 3 winters. My homemade electrics have allowed me to do winter riding in 12 states so far in temps as low as 17 degrees. I thought I'd share my experience here, good and bad.
So anyway, if you've ever thought about doing it, this would be a good time to get started and I'll be glad to walk you through it.

GLOVE LINERS


JACKET LINER


INSOLES


HI/LO SWITCH
 

hemibee

Texas Tiger
Riding for 50 Years
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Tony
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Second round, a little more detail. . .

I've been making my own electrics for 6 years.

It's that time again.

I applied what I've learned to a new version jacket liner I call 3.0. Old 2.0 is still working fine, I wanted to streamline and tidy things
up a bit. So this time I decided to combine my thermal base layer and heated jacket into one garment. I almost never wear the
electrics without the base layer too. I found this Freeze-out brand zippered top they call a "gilet." Its thick poly fleece lined material
is plenty robust enough to hold the wiring. As before I plan to tuck it in like a shirt to prevent the wind from coming up between my
back and the heat. http://www.cyclegear.com/CycleGear/Street/...CFeJDMgodAS4A8Q


For the first time I used a machine zig zag stitch to attach the wires - much neater.


I learned the hard way to take it slow with the machine. Once I hit the nichrome squarely with the needle - the needle won. It was an
easy fix. As with the assembly, I used an unshielded butt connector crimped, then filled with solder and covered with shrink tube.




In order to get the snug fit I wanted I had to settle for sleeves that were too short. So I cannibalized my old army surplus base layer
and sewed the sleeves inside to add a couple inches to the cuffs and to make a double layer up to just below the elbow. This worked
out well as the arms are heated only in the bicep area where I feel the wind the most. Also, I left the glove Y-cord out this time and
attached it to my outer jacket. Now I won't have to don the heated jacket just to power the gloves on shorter commutes or milder
temps. Before I was wearing the jacket liner without turning it on about half the time.


The wiring is essentially the same as the previous version. There are six 54" loops of 26ga nichrome around the body of the jacket
(4 in front, 2 in back) and one 54" loop in the bicep area of each arm. Each loop produces 15 watts. (15 x 8 = overkill)


I noticed on version 2.0 the resistance wire would bulge through the hand stitching as the fabric moved.


This time I did not stitch the top of each section of wire to allow for expansion. I can also give it a pull at the top to straighten it out if
I need to. I hand stitched the wires to the back of the left pocket so I'd be able to store the power pig tail inside. I just machine stitched
through the right pocket since I didn't need it.



The power pig tail runs through the pocket for easy storage.


Here's a shot of the back. As before I took care to ensure there is no wiring at the belt line so I can comfortably tuck it in.


I think I'm going to like this one much better.

Enjoy!
 

hemibee

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Riding for 50 Years
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More Info . . .


I thought I'd share this in case anybody needs clarification. Here's a rudimentary diagram. If you are doing the arms too, just add 2 more loops.
The green represents the nichrome. The black and red are 20ga copper or steel stranded wire to supply power to the nichrome.

It is not necessary to heat the arms but if you do the supply wire should also extend well into the sleeves so arm motion doesn't cause the nichrome to flex and break. The arm supply wires will connect in parallel like so.


Oh, and if you plan to tuck this thing in like a shirt make sure all wiring is done above the belt line. I planned to do this but found in my case it fit snugly enough to prevent cold air from blowing up my back. I just flip the tail up a little to reach the zipper to connect my jacket and pants.
 

DaveM

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It is not very neat looking but I suppose that is not the purpose of it
 
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