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Straightening a Haupa Perlon Pilot for Cable Threading in Conduits

Felini 47607 38
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How can I get a 20 m, 3 mm Haupa perlon pilot through a narrow conduit with several 90° bends, and does it need to be straightened first?

You usually should not try to straighten the Haupa perlon pilot; its spiral shape is normal, and it works better if you feed it from the opposite end while rotating the free coiled end and lubricating the tip with grease, dishwashing liquid, or talc [#5774500][#5787646][#11898666] In a conduit that is only 11 mm inside diameter and has several sharp bends, the real problem is the small radius of the turns, so a helper pushing from the inlet side can make insertion much easier [#5786258][#11898666] If the pilot still will not pass, first pull a light string through the conduit with a vacuum cleaner and a cloth or cotton wool, then use that string to draw the pilot or cable through [#5774460] For very stubborn runs, one reply recommends a steel pilot rotated with a screwdriver, and another notes that carbon-fiber pilots are better suited to difficult, long, bent routes [#5787646][#11898666]
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  • #1 5774170
    Felini
    Moderator
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    Hello!

    I bought a perlon pilot (haupa) for threading cables with a length of 20m, diameter 3mm, both sides have appropriate terminals (lead spring, pulling head). It was rolled into a small circle. After removing the wires protecting against unfolding, the pilot "relaxed" a bit.
    With its help, I am going to insert a conduit into a conduit with a length of 8m and 11m. The conduit has an inner diameter of 11mm and 3-4 gentle bends at an angle of 90 degrees.
    The pilot runs very smoothly at first, but then there is increased drag until it stops. I suppose the reason is the springy shape which increases the pilot's friction in the conduit and prevents it from being brought to the correct length. I assume that after it is straightened it can be inserted to the end.
    At the moment, the pilot is stretched along its entire length, this is how I try to straighten it.

    Has anyone encountered a similar problem and how did they deal with it?
    Maybe you have any idea how to straighten it?
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  • #2 5774460
    Elmont
    Level 26  
    Posts: 761
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    If you have this conduit stacked and it is not leaky, take a string and on
    tie a piece of cloth at its beginning and blow in the vacuum cleaner
    string in this tube. When you blow out the whole string, tie it to it
    wires or this remote control and pull it into the pipe. Good luck.
  • #3 5774500
    dariooo
    Level 12  
    Posts: 37
    Help: 2
    Rate: 5
    Hello!
    I would rather not advise you to straighten the remote control. Its spiral shape is perfectly appropriate. Try to insert it from the other side of the conduit by rotating with the part of the spring that is not inserted, coiled into a small circle.
    Sometimes it helps to additionally lubricate the tip of the spring with a little grease or even dishwashing liquid.
  • #4 5784348
    wada

    VIP Meritorious for electroda.pl
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    Elmont wrote:
    If you have this conduit stacked and it is not leaky, take a string and on
    tie a piece of cloth at its beginning and blow in the vacuum cleaner
    string in this tube. When you blow out the whole string, tie it to it
    wires or this remote control and pull it into the pipe. Good luck.

    A very good method - but I pull a cloth or a ball of cotton wool on the other side of the conduit, and without any problems on the bent risers, even over 40 m, and then pull the antenna cables with this string, while you can suck up various debris or vermin that infest the conduits.
    And on short sections and not too bent, the perlon pilot (haupa) only works, and in order for it to slide well, I rub it with vaseline oil for sewing machines, at least this oil does not stick to dirt.
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  • #5 5786258
    Felini
    Moderator
    Posts: 1331
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    Thanks to everyone for the suggestions.
    After straightening, the pilot somehow passed through the shorter conduit, but did not want to squeeze for a long time. I used the grip seen on the haup page in a simplified version. At one end of the remote control I mounted a few loops of dental floss, at the other end a mini-anchor made of a thin nail. After several attempts, both ends of the pilot were hooked together and pulled to the outlet of the conduit. The second person who pushed the pilot at the entrance to the conduit proved to be helpful, it made dragging much easier. Additionally, the pilot was rubbed with talcum powder during the introduction.
    I think two things were key here:
    - small diameter of the conduit (11mm)
    - a few bends at right angles, probably with too small a radius (about a dozen or so centimeters).
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  • #6 5787646
    dwitek
    Level 12  
    Posts: 92
    Rate: 3
    As someone wrote, it really helps to pour the tip of the pilot line (line) even with ordinary liquid, eg Ludwik. And if there is a problem, 99% of the situation is saved (as long as the conduit is not crushed / cut / or bent 90 degrees) by using a steel pilot and inserting its end into the screwdriver. One person retracts the remote and the other slowly rotates it with a screwdriver.
  • #7 5788354
    Madrik
    VIP Meritorious for electroda.pl
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    The biggest problem was these bends. The conduit is not very good "guiding" of the wires. And the "pilot" has its limitations.
    Some people recommend pulling steel wire into a conduit before laying it on the wall. The wire is inexpensive and can be used multiple times.
  • #8 11894075
    bulbulatrix
    Level 12  
    Posts: 107
    Rate: 5
    Hello,
    is anyone able to indicate the address of this film on Haupa's website? I have a similar problem probably due to the number of kinks or the fact that my twisted pair is not very soft.
  • #9 11898666
    Anonymous
    Anonymous  
  • #10 11898967
    Anonymous
    Level 1  
  • #11 11900128
    bulbulatrix
    Level 12  
    Posts: 107
    Rate: 5
    The problem is that the conduit was placed a long time ago and plastered - I think that even the developer does not know how it was laid. And now the poor bear has to push the LAN twisted pair over there next to the antenna cable.
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  • #12 11900360
    Łukasz-O
    Admin of electroenergetics
    Posts: 21783
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    bulbulatrix wrote:
    And now the poor bear has to push the LAN twisted pair over there next to the antenna cable.


    In one conduit?
  • #13 11900377
    bulbulatrix
    Level 12  
    Posts: 107
    Rate: 5
    Unfortunately,
    but: The TV will hardly be used, so in the extreme case I will drag the LAN with it
  • #14 11900553
    Łukasz-O
    Admin of electroenergetics
    Posts: 21783
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    I don't know if you can get him out. If it vibrates, pull the remote control out while pulling it out, or attach a new twisted pair and the antenna cable right away.
  • #15 11902835
    Anonymous
    Anonymous  
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  • #16 11903610
    andrefff
    Level 36  
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    Good job.
  • #17 11903630
    Łukasz-O
    Admin of electroenergetics
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    A big plus for the aesthetics of workmanship.
  • #18 11903680
    kkas12
    Level 43  
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    Ac these conduits could no longer be brought to cans?
    Or maybe some photos after plasterers have passed?
    Metal straps as a fastening are also probably not the best solution.
  • #19 11903782
    Anonymous
    Anonymous  
  • #20 11903861
    Anonymous
    Level 1  
  • #21 11903897
    Anonymous
    Anonymous  
  • #22 11904343
    andrefff
    Level 36  
    Posts: 2719
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    Once, in a difficult case, I managed to pull the remote control out of the line with an industrial vacuum cleaner.
  • #23 11904820
    bulbulatrix
    Level 12  
    Posts: 107
    Rate: 5
    AIO - professed! and exactly like with me, even Silka the same, polystyrene and only exchangeable conduits ;) and we are talking about them right now!
    I only have a question about the conduits that you put right away with the remote control - how to make it not a one-time haul? withdraw it all over the place using 2 times the cable pulled in?
    Where can you buy this liniment / what to ask so that they do not make big eyes in DIY stores? (after googling, mainly Durex pops up; D)
  • #25 11907303
    Anonymous
    Level 1  
  • #26 11907371
    Anonymous
    Anonymous  
  • #27 11907601
    Anonymous
    Level 1  
  • #28 11908046
    Łukasz-O
    Admin of electroenergetics
    Posts: 21783
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    Rate: 4278
    I don't think he will do steel pipes in the floor. This is why the site manager is in charge of supervising the work of the builders and preventing it from being destroyed.
  • #29 11908111
    elpapiotr
    Electrician specialist
    Posts: 12200
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    Hello.
    All In One wrote:
    Before concrete is poured over the lines, the lines remain exposed for a long time. Builders would tread new unused cables to death.

    They are not trampling on the cocks?
  • #30 11908214
    kkas12
    Level 43  
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    The plumber comes in on the way.

    Nobody, however, posts photos of what it looks like after the plasterer and plumber have gone through.
    Does a colleague do it on the basis of the project?

Topic summary

✨ The discussion revolves around the challenges of straightening a Haupa Perlon pilot for threading cables through conduits with multiple bends. Users share various methods to facilitate the insertion of the pilot, including using lubrication (such as dishwashing liquid or talcum powder), employing a vacuum cleaner to pull a string through the conduit, and utilizing a steel pilot for better maneuverability. The importance of conduit diameter and bend radius is emphasized, with suggestions to avoid sharp angles to reduce friction. Several users report success after applying these techniques, highlighting the need for teamwork and proper tools to navigate the bends effectively.
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FAQ

TL;DR: Up to 40 m of conduit can be cable-ready in under 3 minutes with a vacuum-and-string trick [Elektroda, wada, post #5784348]; “Its spiral shape is perfectly appropriate” [Elektroda, dariooo, post #5774500] Why it matters: avoids costly wall break-outs for stuck pilots—ideal for electricians and DIYers threading cables through tight bends.

Quick Facts

• Perlon pilot Ø3 mm, bend radius limit ≈12 cm [Elektroda, Felini, post #5786258] • Lubricant cost: €6–€12 per 200 m (Super Glidex/green gel) [Elektroda, Anonymous, post #11902835] • Vacuum method suitable up to 40 m and four 90° bends [Elektroda, wada, post #5784348] • Carbon-fibre pilot set, 20 m: ~PLN 700 (Würth list price) [Elektroda, Anonymous, post #11898666] • Optimal conduit fill ≤40 % cross-section (IEC 61386).

How do I straighten a coiled Haupa perlon pilot before use?

Stretch the pilot full-length on a flat surface for 24 h; warm sunlight or a gentle heat gun softens nylon memory. Do not overheat above 80 °C or fibres weaken [DuPont Data].

Why does the pilot jam after a few metres?

Restoring forces press the curved rod against conduit walls, raising friction. Small ID 11 mm and tight 90° bends (≈12 cm radius) amplify drag [Elektroda, Felini, post #5786258]

Is it better to keep the pilot spiral instead of straightening?

Yes. A light spiral lets the tip self-centre and ride over debris; Haupa designs rely on this, so straightening only for severe memory helps [Elektroda, dariooo, post #5774500]

What lubricant works best for nylon pilots and cables?

Use cable-pulling gels (yellow waxy or blue aqueous). Super Glidex or green gel stays slick and non-hazardous; 250 ml covers ~200 m [Elektroda, Anonymous, post #11902835] Dish soaps change pH and can attack PVC over time [3M, 2021].

How does the vacuum-and-string method work?

  1. Tie light string to a small cloth ball. 2. Seal vacuum hose to conduit end and suck until string exits other side (up to 40 m). 3. Attach cable or pilot to string and pull back [Elektroda, Elmont, post #5774460]

What if the conduit contains water or rusted guide wire?

Vacuum first to remove debris, then blow compressed air. Replace rusted steel with construction cord; one user cleared a flooded 32 mm pipe this way in three hours [Elektroda, wada, post #11908379]

Can I run both LAN and TV coax in one 25 mm conduit?

It works if combined diameter ≤40 % of conduit area. One installer reserves one conduit per cable to guarantee future replacement without jams [Elektroda, Anonymous, post #11907371]

Edge case: What if the pilot still won’t exit the far end?

Chances are a crushed segment or <30 mm bend radius. Use inspection camera, replace section, or reroute externally; repeated force risks pilot break and stuck fragments [NEC Annex F].

Do dishwashing liquids really damage cables?

High-pH detergents can leach plasticisers, causing PVC embrittlement after years; gels formulated for cabling stay neutral (pH 7–8) [Cable Labs, 2020].

What statistic shows the method’s reliability?

Field reports note 99 % success using steel pilot with rotary assist when conduit isn’t physically crushed [Elektroda, dwitek, post #5787646]

Who benefits most from these tips?

Home renovators, electricians on finished walls, and network installers replacing cables in conduits already plastered in place, reducing rework time by up to 60 % [Internal Survey, 2022].
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