Old 11-26-14, 12:04 AM
put our Heads Together
cerewa's Avatar
Join Date: Jun 2003
Location: southeast pennsylvania
Posts: 3,155

Bikes: a mountain bike with a cargo box on the back and aero bars on the front. an old well-worn dahon folding bike

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Exclamation A lot of little solder connections

This is not a terribly complex problem but the solution is not all that elegant. You can (have someone do this for you or) cut open the wires,add length, and solder them back. Doing so will preserve the connectors that came with the bike,but give you longer wires. Buy heat-shrink tube that can cover your wires and the area around the splice. Solder your extra length of wire to one end of the wire you cut and then the other. Each brake may have a double wire or a single. You have to add to every single wire you choose to lengthen, and add heat shrink tube so that your strands don't touch each other. The display may have 8 wires or so and you must match the wires up as designed, or it won't work. The throttle,I assume, has 2 or 3 wires which must be connected correctly. The existing wires may or may not be color coded in a way that makes it easy to connect them correctly.

The "wire harness" part you mention might be useful in the following way: if it has wires for all your parts and you buy an extra wire harness, you could cut upper connector off one,lower connector off the other, and end up with the right amount of wire when splicing together. If so, you'd end up having to solder fewer times BUT you'll have to somehow identify every single wire that is to be soldered and make room for your solder, your tubing (to keep wires separate which prevents short circuit) and the doubled up wire where you made the solder connection.

Either way the process will likely make the bike non rainproof if it was rainproof before. (Meticulous use of the right kind of glue at connections may be enough to waterproof the connections)
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