Falconer Electronics, Inc (FEI) is known for Wire Harness Assembly Excellence & Reliable Performance. Our team at FEI assembles custom wire harnesses in a variety of lengths, wire gauges, and colors. Depending on the need, the length of our wires can vary from as small as 3 inches to as long as required. We also offer a variety of wire gauges, from a minimum of 24 gauge up through the larger 00 cable sizes. As a result, we can implement into our harnesses to best meet the needs of our customers.

Our mission is to produce superior wire harness assembly built to our customer’s specifications and expectations. With over 30 years of experience, our expert staff will produce wire harness solutions at the most economical cost while maintaining the highest quality of workmanship and on-line delivery. Especially important, customers consistently rate our accuracy of products and services at near perfect levels.

Wire Gauge

Tips for Choosing the Correct Gauge of Wire for the Job

Have you been looking into a wiring project? Do you know what gauge of wire is best suited for your needs? Our tips can help you in the choosing process of wires!

**Always have electrical projects looked over by professionals before any installation or use to prevent injury or fire**

1: What type of project are you doing?

There are many different types of wiring projects. Depending on whether you are working on home wiring or building your own robot, there is a difference of what type of wire is required. For example, some projects include:

  • Home wiring
  • Robotics
  • Computers
  • Vehicles

2: How much space do you need for wiring?

To begin with different housings for different projects will vary in size. Due to the wire size, the space needed to house them will vary. If you think about a light switch, some have a single switch and therefore only need enough room for the wires of that one switch. However, there are light switches that have multiple switches. Therefore, the space required for the wiring of a multi-switch receptacle is larger than that of a single switch receptacle. In order to do a job properly, you need to be aware of how much space you have to work with and really need. If you are working on home wiring that requires a larger current as opposed to a robot that requires less current the space needed is different because the wire size will be different.

3: How are wire gauges calculated?

Especially relevant is the fact that as wire increases in physical width, the gauge of that wire will decrease in numerical value. While this does seem backward it’s really not. Due to the wire drawing process, the number of operations that it takes to get it to that physical size is the numerical gauge of a wire. As a result, gauges are larger or smaller than the physical size.

Wire Gauge

4: What are large and small gauged wires used for?

There are also many different gauges of wire. Consequently, they have many different uses.

Uses for some smaller gauges (larger physical sizes) of wire:

  • Electrical lines (like those you see outside attached to power lines)
  • Heavy duty automobiles like trains, larger armored trucks
  • Home wiring

Uses for some larger gauges (smaller physical sizes of wire):

  • Computers
  • Radios
  • Phones
  • GPS
  • Mp3 player
5: How much amperage do you require?

There are different factors that determine the required amount of amperage:

  • Amperage= Wattage/Volts
  • What current do you need for your project
  • Where the wire is going
  • Where the wire is coming from

In addition to these tips you can learn more about wire gauges by looking back to our previous blog Why Do Wire Gauge Sizes Seem To Work Backwards?

In conclusion, the chart below will be helpful in deciding which wire is appropriate for your specific job.

AWG Cable/ Conductor Size Chart

AWG Diameter 
[Ohms / 1000 ft]
[Ohms / km]
 Max Current 
Max Frequency
for 100% skin depth
 0000 (4/0)0.4611.6841070.0490.16072302125 Hz
000 (3/0)0.409610.40384850.06180.202704239160 Hz
00 (2/0)0.36489.2659267.40.07790.255512190200 Hz
0 (1/0)0.32498.2524653.50.09830.322424150250 Hz
10.28937.3482242.40.12390.406392119325 Hz
20.25766.5430433.60.15630.51266494410 Hz
30.22945.8267626.70.1970.6461675500 Hz
40.20435.1892221.20.24850.8150860650 Hz
50.18194.6202616.80.31331.02762447810 Hz
60.1624.114813.30.39511.295928371100 Hz
70.14433.6652210.50.49821.634096301300 Hz
80.12853.26398.370.62822.060496241650 Hz
90.11442.905766.630.79212.598088192050 Hz
100.10192.588265.260.99893.276392152600 Hz
110.09072.303784.171.264.1328123200 Hz
120.08082.052323.311.5885.208649.34150 Hz
130.0721.82882.622.0036.569847.45300 Hz
140.06411.628142.082.5258.2825.96700 Hz
150.05711.450341.653.18410.443524.78250 Hz
160.05081.290321.314.01613.172483.711 k Hz
170.04531.150621.045.06416.609922.913 k Hz
180.04031.023620.8236.38520.94282.317 kHz
190.03590.911860.6538.05126.407281.821 kHz
200.0320.81280.51810.1533.2921.527 kHz
210.02850.72390.4112.841.9841.233 kHz
220.02540.645160.32616.1452.93920.9242 kHz
230.02260.574040.25820.3666.78080.72953 kHz
240.02010.510540.20525.6784.19760.57768 kHz
250.01790.454660.16232.37106.17360.45785 kHz
260.01590.403860.12940.81133.85680.361107 kHz
270.01420.360680.10251.47168.82160.288130 kHz
280.01260.320040.08164.9212.8720.226170 kHz
290.01130.287020.064281.83268.40240.182210 kHz
300.010.2540.0509103.2338.4960.142270 kHz
310.00890.226060.0404130.1426.7280.113340 kHz
320.0080.20320.032164.1538.2480.091430 kHz
330.00710.180340.0254206.9678.6320.072540 kHz
340.00630.160020.0201260.9855.7520.056690 kHz
350.00560.142240.0163291079.120.044870 kHz
360.0050.1270.0127414.813600.0351100 kHz
370.00450.11430.01523.117150.02891350 kHz
380.0040.10160.00797659.621630.02281750 kHz
390.00350.08890.00632831.827280.01752250 kHz
400.00310.07874 0.00501104934400.01372900 kHz

If you are interested in designing your own wire harnesses check out our new Wire Harness Estimator to get a quote!

If you need more information before you get started check out our blog on The Wire Harness Estimator Components Defined

You can also learn more about our pre-designed wire harnesses by checking out our Wire Harness Page!

For more info on electronics manufacturing, please connect on FacebookTwitterGoogle+, and LinkedIn.

**Always have electrical projects looked over by professionals before any installation or use to prevent injury or fire**   

Why Do Wire Gauge Sizes Seem To Work Backwards?

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Something that has been a constant source of confusion within many circles, is the question of why do wire gauge sizes seem to be the opposite of what we think they should be? As a wire increases in physical width the gauge of that wire will decrease in numerical value. This seems backwards but, there must be an explanation to this that makes some form of sense.

Determining Wire Gauge Sizes 

Given an example of the wire gauge chart in Figure 1.1 we can see there is an extreme difference in physical size between a 0 gauge wire and that of a 30 gauge wire. The physical size of the 30 gauge is substantially smaller than that of the 0 gauge wire. Why is this?

The physical size of a wire is defined by the number of operations that it takes to get it to that physical size. This process means that a 30 gauge wire is much smaller in size than a 0 gauge wire. This process is called “Wire Drawing” and it looks like Figure 1.2. “Wire Drawing” is what gives us all of the different gauges that are seen in Figure 1.1.

A way to think about the wire drawing process is to think of the process of taffy pulling. Just like that sugary deliciousness, the wire starts off as one larger wire mass. Also, like taffy pulling wire drawing stretches and decreases the physical size of the wire making it longer and thinner. The process of wire drawing and decreasing the gauge of a wire also reduces the current that is traveling through the wire. By reducing the current in smaller gauged wires there is a decrease in the amperage that can be handled.


wire gauge

Figure 1.1 (Standard Wire Gauge Chart)


Figure 1.2 (Wire Drawing to Decrease Wire Gauge) (Kingway)

Now that you know how wire gauges are measured you are ready to start your own wire harness journey!

If you are interested in designing your own wire harnesses check out our new Wire Harness Estimator to get a quote!

If you need more information before you get started check out our blog on The Wire Harness Estimator Components Defined

You can also learn more about our pre-designed wire harnesses by checking out our Wire Harness Page!

Wire Harness Department Top 20 Playlist


Last week, we discussed creating a positive work environment. Music certainly helps the cause. Whistling while you work keeps the day humming along.

What do you listen to while you work? We have compiled the top 20 songs that the Wire Harness Department listens to while building wire harnesses.

It is this collection of songs that keep our workers focused while they work.

Check out our variety of songs and you may just find a new favorite for yourself!


20: White and Nerdy- Weird Al Yankovic

 Related image

19: YMCA- Village People

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18: Drift Away- Dobie Gray

 Image result for dobie gray drift away

17: Hand Clap- Fitz and the Tantrums

 Image result for fitz and the tantrums handclap

16: Wanted Dead or Alive- Bon Jovi

 Image result for wanted dead or alive bon jovi

15: Love Boat- Jack Jones

 Image result for who sings the love boat theme'

14: Purple People Eater- Sheb Wooley

 Image result for purple people eater

13: Amish Paradise-  Weird Al Yankovic

 Image result for amish paradise

12: Jumping Jack Flash- The Rolling Stones

 Image result for rolling stones jumpin jack flash

11: Carry On My Wayward Son- Kansas

 Image result for carry on my wayward son kansas

10: Love Shack- B-52s

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9: I’m Gonna Be (500 miles)- The Proclaimers

 Image result for 500 miles

8: Sweet Caroline- Neil Diamond

 Image result for sweet caroline

7: Fight For Your Right- Beastie Boys

 Image result for fight for your right to party

6: Eye of the Tiger- Survivor

 Image result for eye of the tiger

5: Hey Jude- The Beatles

 Image result for hey jude

4: Me and Bobby McGee- Janis Joplin

 Image result for me and bobby mcgee

3: One Week- Barenaked Ladies

 Image result for 1 week barenaked ladies

2: Simple Man- Lynyrd Skynyrd

 Image result for simple man lynyrd skynyrd

1: Bohemian Rhapsody- Queen

  Image result for bohemian rhapsody

Now that you have checked out our Wire Harness Department’s favorite songs you may be interested to do some wire work of your own! Check out our Custom Wire Harness Estimator for a fast quote to get you started on your next project!

Also, check out our blog for more interesting news and articles like our Top 10s, What Not to Dos, and much more!

For more info on electronics manufacturing, please connect on FacebookTwitterGoogle+, and LinkedIn.

Wire Harness Estimate

Do You Need a Wire Harness Estimate, Pronto?


Need a price on a Wire Harness Assembly, like RIGHT NOW?! Traditionally, receiving a Wire Harness Estimate could take hours or even days. Well, thanks to some hard work and innovation that problem is now solved. You can now receive a Wire Harness Estimate within minutes (or even seconds depending on how fast you type). Stop by and check out the brand new Falconer Electronics Wire Harness Estimator.

Wire Harness Estimate in 6 Simple Steps 

The Wire Harness Estimator offers you a simple 6 step process. With each step, you can easily enter product information. Once complete, you hit submit. Within seconds your Wire Harness Estimate will be waiting for you in your email box.

Wire Harness Estimate

  1. Select your wire
  2. Enter the number of wires
  3. Select your terminals
  4. Choose add-ons – such as sleeving, heat shrink, labels, or wire ties
  5. Don’t see an item you need – this step you can type in a request
  6. Submit

At any time you are also free to submit a drawing.

Creating a prototype?

Testing a new product?

Need a Wire Harness Estimate quick? No problem. You can breeze through the Wire Harness Estimator completely free of charge and no obligations.

Questions on Wire Harness Components? Click here.

Custom Wire Harness Assembly 

What type of industries do we serve? Our wire harnesses can be found in the healthcare industry, auto and truck lighting, heating systems, locomotive products and much more.  

Commercial Power Strips

Commercial Power Strips manufactured by Falconer Electronics can be found working relentlessly at numerous major brick and mortar retail stores at product displays. We produce our own wire harnesses for all of our power strips.

Portable Work Lights 

We even produce wire harnesses for our own proprietary product line of portable work lights. This line includes magnetic trouble lights and magnetic spotlights.

MLC-50-C3 Trouble Light


Thank you for reading this post on Wire Harness Estimate. For more info on electronics manufacturing, please connect on FacebookTwitterGoogle+, and LinkedIn.

Supplies Components

Who Supplies Components When Outsourcing Production? – Part 7


Supply or not supply? That is the question for today.

When outsourcing to a custom manufacturer, a common question occurs, “Who Supplies Components When Outsourcing Production?” Do you supply your own parts and materials or is it more cost-effective for the custom manufacturer to purchase materials? We will address this topic from the perspective of a Wire Harness Manufacturer

This is our continued series on Outsourcing Wire Harness Manufacturing. Below includes links to previous topics on this discussion: 

Outsource Your Wire Harness Assembly Process – Part 1

Selecting a Wire Harness Manufacturer – Part 2

How to Find a New Wire Harness Manufacturer – Part 3 

Interviewing a Wire Harness Manufacturer – Part 4

Discreet Questions to Determine Character Compatibility and Financial Viability – Part 5

Touring a Wire Harness Manufacturer – Part 6

What if I want to supply my own products such as wire, connectors and other components to save money? 

Supplying your own products to a custom manufacturer offers several positives and negatives. It works best to communicate clearly with the manufacturer on the pros and cons of either option. 

The question is do you really save money?  One-size fits all does not apply here. There are many variables to consider which option makes the most sense (or more importantly – make the most CENTS). 

Pros and Cons 

Let’s take a look at the Pros and Cons of supplying your own parts and components: 


Several benefits fall in your favor by taking the initiative to order and supply your own parts when outsourcing: 

  1. You control the ordering process and supply chain. 
  2. Ordering your own parts allows you to have full disclosure of pricing on the cost of goods. 
  3. First-hand knowledge of availability or stock-outs on your product. 
  4. Better control over delivery times. 
  5. Negotiate your own discounts with the vendor. 


Ordering or supplying your own parts may be welcomed by the manufacturer. On the other hand, this approach could be disruptive to the manufacturer. Here are a few negatives to consider: 

  1. The time you spend ordering parts. 
  2. The time you spend coordinating deliveries. 
  3. Lost opportunity of volume discounts available to the manufacturer due to their purchasing power.
  4. Product knowledge and expertise that the manufacturer possesses.
  5. The variety of shipments arriving at manufacturer at different times throws off their production schedule for your product. 
  6. The receiving department at the manufacturer must be informed of delivery. This communication is crucial for the manufacturer in order to properly schedule production of your products. 
  7. The manufacturer must implement a means to monetize the receipt of your goods that you order. It is in neither parties interest to not account for labor, handling, and the overhead expense of receiving and storing goods. 

Supplies Components

An important question to ask yourself: Is your time better spent focusing on other areas of the business? Did you partner with a company that you trust enough to delegate the purchases to the custom manufacturer? 

You partnered or hired the custom manufacturer due to their proficiency, expertise, and ability to deliver a quality product on time. Is it worth your time, hassle and energy to locate new vendors and product in areas that are either new to you or where you are lacking purchasing power and strong vendor relationships?

For more info on electronics manufacturing, please connect on FacebookTwitterGoogle+, and LinkedIn.