Dave – I believe the originals were spot welded. The band on my Marconi one was broken when I got it. Otherwise it looks like it came out of the factory. I just butt connected them with a piece of heat shrink tubing. Worked great as far as keeping the loop together even when the wheels were turning. I doubt if it would be noticeable in operation as there is only a microscopic gap where the ends were connected. Attached is a photo from a You Tube video that shows a similar connection style. Whatever you use, it has to be able to bend a small amount so it will go around the wheels. Nice project. Good luck with it. Remember, the pickup coils can be copper. The earphones have to have a low resistance between 100 to 200 ohms. 73 – Mike

Thank you for sending this, Mike.

Glad to hear that 40-gauge is not nessesary.

Please-  how are the ends of the individual wires joined 

to form one of the loops?

TNX DE Dave AB5S