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Frame Wiring and Embedding

Begin by drilling 1/8″ diameter holes centered in the end bars. 5 holes are drilled on 9-1/8″ (deep) end bars, evenly spaced. 3 holes are drilled on 6-5/8″ (medium) end bars, evenly spaced. A simple jig is made by using a scrap piece of wood and making marks on it that equate to the spacing of the holes to be drilled.

Once the holes are drilled, install brass eyelets into the holes. A setting tool can be purchased.

To install the wire, start by setting a small headed nail just above the top eyelet on one side of the frame.

One the opposite side of the frame, install a nail directly above the bottom eyelet, leaving both nails standing about an 1/8″.

Starting at the bottom, thread a piece of wire through the bottom eyelet (where the nail is) and across to the opposite side (bottom eyelet), up to the middle eyelet and through to the opposite side eyelet, repeating till you reach the top eyelet where the nail is. Cut the wire from the spool leaving a few inches extra on each end. Wrap the wire tab around the bottom nail a few times.

Drive the nail all the way in and break off the excess wire tab.

Pull the wire hand tight through all the eyelets, then wrap the end of the wire around the top nail several times.

Drive the nail all the way in and break off the excess wire tab. Stretching the wire with the nail between the eyelets, drive the nail through the end bars as shown.

Repeat on the other side. This will take all the slack out of the wire.

Various contraptions can be made to provide a low current to the wire. Battery charger, transformer, here a clothes iron.

Place the electrical clamps on the wire at each end. Insert a piece of wax foundation into the top groove, laying on top of the wires. Give the wire a few seconds electrical charge. You will see the wires start to melt right into the wax. Gently push the wax down onto the wires as they cool to make sure they are embedded.

Wires embedded into the wax foundation.