I gather from your reply Robo that you install the foundation after wiring the frames :?: ?
Yes, I wire the frames before installing the foundation.
Here is my frame wiring jig. Click image for larger view
I too was having trouble getting the wire tight without breaking it. So I installed a little block on the jig that allows me to wedge the bottom bar down, and pre-bow the sides of the frame. I then wire the frame up snug, and when I remove the frame, the wire becomes nice and tight.
Once I get all the frames wired up, then I install the foundation by weaving it through the wires (wires on alternating sides of the foundation)
I have an old electric embedder that I believe came from Kelly. It is just a piece of wood with brass spring tabs at the ends that just fit inside the frame rails. There is a switch in the middle that completes the circuit. There are also metal tabs along the edge that push the hot wire into the wax.Click image for larger view
The embedder is fed by a 12V transformer.Click image for larger view
With this I can only do one wire at a time, but it is relatively quick. I have seen jigs that do all the wires at once, but I have my doubts how well they work. First of all, they do not have any means of pushing the hot wire in, so unless the natural center of the foundation and the natural center of all 4 wires are in the same plane, you won't get good results. Secondly, It is very easy to overheat the wire and melt right thru the foundation. Like cutting thru it with a knife. I prefer the control of doing one wire at a time.