Mike,

I used the same glue for the aluminum tubing, but I learned when I removed 
the chromed rack for another bike and disassembled the wiring, that the 
glue doesn't hold as tenaciously to the smooth chrome as it does other 
substrates.  It seems to bond aluminum and plastics extraordinarily well, 
especially if you rough up the surfaces lightly with sand paper beforehand.

As for the connectors, yeah, I figured I'd solder them on after threading 
through the guides.  For flat wire it allows me to feed the connectors 
through the guides, but for round coax wire with the same OD as the guide 
ID, connectors can't pass through.  If you size up the aluminum tubing a 
bit bigger, you can pass the connectors through. I recently switched to 2mm 
banana plug connectors for anywhere I feel I need a removable junction.   
They are very robust and hold up extremely well, but you have to be 
comfortable soldering... they have no strain relief mechanism built in. 
They're also slender and don't result in a bulky looking junction.

http://www.amazon.com/Neewer-Plated-Bullet-Banana-Connectors/dp/B00GTN72ZS

Here's one in use at my rear fender...

<https://farm9.staticflickr.com/8591/15476360069_4c78e0fa7e_z.jpg>

<https://farm8.staticflickr.com/7485/15660310091_de9ca57235_z.jpg> 

Anton



On Sunday, December 28, 2014 9:17:59 AM UTC-5, Mike Gillespie wrote:
>
> Hey Anton, 
>
> I really like your wiring ideas, and this topic is timely for my 
> winter project as well.  So, I'm curious how you thread your wiring 
> through those 3mm ID tubing and heat shrink pieces.  My light has 
> those spade lugs for connecting to a Schmidt hub, and I'd like to have 
> the capability to remove lights and even fenders perhaps at times.  A 
> "hard-wired" job means cutting and then resoldering terminals each 
> time. 
>
> I've found these, but not sure how they might perform in this situation. 
>
> http://www.amazon.com/Spade-Crimp-Terminals-Wiring-Connectors/dp/B00976CPWO/ref=pd_sim_indust_4?ie=UTF8&refRID=0M3K5ANMFXRZX02EEV5G
>  
>
>
>
> http://www.amazon.com/Amico-Female-Spade-Terminals-Connectors/dp/B00ACD9SQ2/ref=pd_sbs_indust_1?ie=UTF8&refRID=0M3K5ANMFXRZX02EEV5G
>  
>
> Anyone have experience in building a more modular lighting system 
> utilizing Anton's tubing ideas? 
>
> Oh, and one more question...do you use the same adhesive on aluminum 
> tubing as heat shrink tubing?? 
>
> Thanks, 
> Mike 
>
>
>

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