Di2 Wire Routing

[MLReed]

I am working on cleanly routing di2 wires on a new frame. I'd like to have the "downtube wire" enter the top tube just before the rear brake cable stop. Then, run it back into the head tube and down into the downtube. I've run some rough numbers, and it looks like I won't have enough clearance in the head tube to run a wire inside of it. Before I abandon the idea, I wanted to run it by the group in hopes that someone could tell me that I am wrong.

My headtube is 36mm. I'll be using an 1-1/8" steerer. I don't have a di2 wire, but I am hearing that they measure 2.7mm. This would mean that I would have .1mm of interference.

Can anyone confirm the wire OD the latest Di2 generation?

Thanks in advance.

[Mark Kelly]

The ones I have ready for install measure 2.63 - 2.66 mm by my calipers.

[wsteve464]

If you really have your heart set on internal routing you can strip off the black outer insulation from the E-tube and have 2 smaller wires to run through the head tube. The black insulation is pretty tough and you would need to be careful not to cut the insulation on the inner wires. Alternatively you can cut the Di2 wire and solder in an extension using small gauge wire, like the wire inside a usb cable. I just finished a Di2 installation with splices to do the same sort of thing the only wire showing is at the derailleurs.

Good luck

[MLReed]

The ones I have ready for install measure 2.63 - 2.66 mm by my calipers.

Thank you, Mark!

[MLReed]

If you really have your heart set on internal routing you can strip off the black outer insulation from the E-tube and have 2 smaller wires to run through the head tube. The black insulation is pretty tough and you would need to be careful not to cut the insulation on the inner wires. Alternatively you can cut the Di2 wire and solder in an extension using small gauge wire, like the wire inside a usb cable. I just finished a Di2 installation with splices to do the same sort of thing the only wire showing is at the derailleurs.

Good luck

Great ideas. Much appreciated.