So I hunted down the spec for the 16awg FEP wire in question and am told it's 2.3mm in diameter, including the Teflon insulation (I'll firm that up once the cable gets here). Got 200 feet of it on its way, as well as a smaller amount of 22awg and 24awg at 40 and 80 feet, respectively. Want to see how well the smaller stuff works.
Now to develop the artwork for the cable combs for the 16awg size, keeping pitch in mind. Not sure if I'm going to use 0.08 steel or aluminum or possibly even 0.09 Delrin (black or white), but the artwork should work with all of them with adjustments that can be made relatively easy, if needed:
The taller version is sized @ 4.2mm pitch, which aligns with the motherboard plug, if one is needed there or close to it. The shorter version tightens up the group, for use further away from that plug. The outside grey areas are about as small as it gets given the resolution of the waterjets/lasers planned for use. The areas in grey will either be painted white, black, or perhaps some other color; haven't made up my mind at this stage.
That said, the same source artwork can be used for the other cables, just need to make sure conductor count and pitch are correct for the different sizes.
Acrylic/printed combs are out of the question because they’re just too darn fragile at these sizes. Sewing also wouldn't work well in this application because of the Teflon insulation.
Pinouts and full system schematic in work as well, tips on the way for my Pace just in case I do decide to rewire all of my fans.Edited by iamjanco - 4/8/17 at 2:03pm