Producing your own cables are not difficult nor that dark a science. High quality cables can be made at different cost levels allowing you to get the best that meets your budget.
We have woven wire covering including some that have a soft feel. Several attractive mixed color combinations to give your work a distinctive look.
An example for speaker cable would be using Alpha 12 awg tinned stranded copper wire (12-PVC-12GAG&Y) . Composed of high quality copper and a pvc insulation,
this cable is easy to prepare and when used with Philmore crimp terminals 5-3-652064, 5-3-652065, 5-3-652067 (choose the stud size you need). These crimp connectors are made of pure copper and offer good sonic performance.
You can also use combinations of copper and silver wire. We do suggest ground return should be 1 guage heavier than the signal line. Example: 22 ga. signal line with a 20 ga. return.
Litz cable is strands of copper individually insulated from each other. Preparation requires removal of the insulation at the solder point. This can be accomplished by scraping off the insulation with a sharp knife or razor blade (after fanning the wire to lay flat) then apply solder after coating the wire with a little radio grade solder flux. Apply a 40w soldering iron tip to burn off the flux and insulation.
Litz wire we stock is found in (pop-up page): Litz wire
This a thin diameter wire and would be suitable for headphone cable.
You can use Qualitek lead bearing solder - 50-6200, 50-62521 50-32521 or lead free eutectic 50-21700 or 50-21750. Also available is the high grade WBT 800 audio solder with 4% silver content with high flux activity.
This write up is incomplete