Ken's Heated Base Layer 3.0 - Wrist Twisters
 
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post #1 of 28 Old 11-11-2013, 06:57 AM Thread Starter
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Ken's Heated Base Layer 3.0

I've been making my own electrics for 6 years now. https://www.wristtwisters.com/forums/...ear-28728.html

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. FREEZE-OUT - Base Layer Zipped Gilet - Tops - Base Layers - Street - CycleGear - Cycle Gear



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.

Anyway, it's all here: Homemade Heated Glove, Jacket & Boot Liners - kphenix

Enjoy!
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post #2 of 28 Old 11-11-2013, 07:19 AM
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Very nice Ken. Looks like very nice quality.

I haven't had to break out the heated gear yet. Soon though!

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post #3 of 28 Old 11-11-2013, 07:52 AM
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Thank you for the detailed write-up!

Where do you buy the Nichrome wire? (sorry if I missed that).

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post #4 of 28 Old 11-11-2013, 08:35 AM Thread Starter
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Originally Posted by MF1VE View Post
Thank you for the detailed write-up!

Where do you buy the Nichrome wire? (sorry if I missed that).
I posted my recent invoice on my other heated gear thread. It's all in the captions of my smugmug pics too.
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post #5 of 28 Old 11-11-2013, 07:13 PM
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nice work Ken

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post #6 of 28 Old 11-11-2013, 09:50 PM
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Very nice Ken. I'm gona have to try to make my own gear one of these days.

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post #7 of 28 Old 11-12-2013, 03:28 PM
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nice ken, I think it is supose to be 28f tomarrow morning. Ride up to my place and try that thing out. .... Hey i may try my stuff out in the morning too. lew

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post #8 of 28 Old 11-12-2013, 09:55 PM Thread Starter
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nice ken, I think it is supose to be 28f tomarrow morning. Ride up to my place and try that thing out. .... Hey i may try my stuff out in the morning too. lew
Yeah, I finished it just in time. Mid 30's forecast here in the morning. I'll be out testing my heated stuff for sure.
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post #9 of 28 Old 11-13-2013, 08:24 AM
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It was 24 this morning on my ride into work, with no heated gear! I had 4 layers on plus my riding jacket. I really need to get some heated gear. Whatcha doin' with your 2.0 stuff Ken?

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post #10 of 28 Old 11-20-2013, 08:51 PM Thread Starter
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Another change of plans. I had intended to tuck the heated liner into my new pants but after trying and returning two pair of touring pants I am left with my old beloved but snug ReV'it! Dakar pants for another season.So again I employ the 360 conjoining zipper - this time without cutting off the tail. I am pleased.






The Freeze-Out Gilet is a snug enough fit that no wind could blow up the back but what the heck - my pants are equipped with this peripheral zipper so I might as well use it.
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post #11 of 28 Old 11-25-2013, 08:00 PM Thread Starter
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UPDATE:

We've had a few wet days around the 40 degree mark. I've had a chance to test the new electric base layer wearing a thin Nike Combat long sleeve shirt under it. The warmth gets to my torso so much better now. I'm also very impressed with the Freeze-out fleece - so much so I bought the matching bottom. I know most Cycle Gear stuff is poor quality - but I highly recommend this Freeze-Out brand thermal wear.
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post #12 of 28 Old 11-25-2013, 08:19 PM
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Meanwhile in Canada....


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post #13 of 28 Old 11-25-2013, 09:06 PM
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Meanwhile in Canada....
Lol. Just so everyone knows, that is not me! Looks like Mrt.81 tho. :P

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post #14 of 28 Old 11-25-2013, 10:51 PM
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Sorry, I think your mistaking me for someone else. Looks more like Dave the shit disturber...

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post #15 of 28 Old 11-25-2013, 11:08 PM
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Sorry, I think your mistaking me for someone else. Looks more like Dave the shit disturber...
Lol.

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post #16 of 28 Old 11-26-2013, 08:30 PM
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Sorry, I think your mistaking me for someone else. Looks more like Dave the shit disturber...
I hope you don't mean me. I'm no where near that white! Lol

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post #17 of 28 Old 11-26-2013, 10:46 PM
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Quote:
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I hope you don't mean me. I'm no where near that white! Lol
He was talking about you. Retaliate Dave! Don't take his shit. Lol.

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post #18 of 28 Old 11-26-2013, 10:46 PM
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Quote:
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I hope you don't mean me. I'm no where near that white! Lol
Don't worry, Dave the shit disturber is a guy I work with.
I was wondering if you would comment on this...

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post #19 of 28 Old 11-26-2013, 10:52 PM
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Don't worry, Dave the shit disturber is a guy I work with.
I was wondering if you would comment on this...
Uh huh, sure. Nice cover.

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post #20 of 28 Old 12-16-2013, 06:47 AM
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It was 24 this morning on my ride into work, with no heated gear! I had 4 layers on plus my riding jacket. I really need to get some heated gear. Whatcha doin' with your 2.0 stuff Ken?
I appreciate you setting me up with your 2.0 linere. It has been working really well, till this morning. I guess there's a break in the wire somewhere. I'll try and trace it down on my next break. Any suggestion on places that may be prone to fail, a good place to start?

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post #21 of 28 Old 12-16-2013, 11:39 AM
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I found a break in the nichrome in the left arm and fixed her up. The liner is still dead though. I can only find two other areas that might be the issue. A small section of bare wire, or the plug. How likely is it that the plug is bad?

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post #22 of 28 Old 12-16-2013, 07:10 PM
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Just my luck. Our radio shack has every size DC coxial plug...except M(5.5mm x 2.5mm), which is the one I need!

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post #23 of 28 Old 12-16-2013, 09:24 PM Thread Starter
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Dang man! I wore it just before I boxed it up and it worked. Sorry. If the whole thing is dead the break has gotta be in the plug or close to it. I've heard about others having problems with those Radio Shack plugs. I'd get extension cables from Gerbing or Warn and Safe and cut them to fit. The molded plugs are much better.

http://gerbing.com/collection/access...on-cord-2.html


Extension Cord 1' - Collection | Gerbing Thermovelocity Protection


If I had kept it I probably would have gone over all the connections.
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post #24 of 28 Old 12-18-2013, 09:22 AM
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Wow pretty innovative. I too have found ome of the radio shack parts to not be up to par..

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post #25 of 28 Old 12-19-2013, 05:03 AM
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The plug ended up being the problem. I finally found a store that had a couple in stock. Got everything soldered and heat shrunk last night. The liner worked exceedingly well this morning, 24 degrees. Actually had to turn it down a little. I ordered one of the Gerbing extensions, but it hasn't arrived yet. Thanks again Ken.

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post #26 of 28 Old 12-19-2013, 06:26 AM Thread Starter
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COOL! . . . . I mean, WARM! I love happy endings.
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post #27 of 28 Old 02-15-2014, 07:40 PM Thread Starter
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Poor 3.0 got run over countless times on the Pacific Coast Highway. It got me home nice and toasty but then a number of breaks immerged. I didn't miss the loss of heat in the arms so I removed those loops. Then I repaired breaks in the torso. Good as new.

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post #28 of 28 Old 03-01-2014, 01:57 PM Thread Starter
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Quote:
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Poor 3.0 got run over countless times on the Pacific Coast Highway. It got me home nice and toasty but then a number of breaks immerged. I didn't miss the loss of heat in the arms so I removed those loops. Then I repaired breaks in the torso. Good as new.




Now for a little housekeeping. The day I bought the cyclegear base layer I laid it on a burning candle and burned a hole in the right arm. Here's the repair.



I'm just not into patches but I thought if I could find one I really liked, one I had to earn I'd cover that spot with it. Here it is.

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