Why do you feel the need to re-wire them? New Black Diamond wired hexes are $10-$16 each,wired stoppers are $9-$10. I can't imagine any competent person replacing the wires for much less than that. Factor in shipping or travel to and from wherever the repair person is, and replacing wires on passive pro starts to look like false economy.
cause economy != ecology? Sure, it's cheaper to produce half-finished parts in america, ship them to china, have them anodised and assembled there (and likely dump the anodising acids in a river) and ship them back than to take a piece of cordalette and tie a double fisherman to an already produced but still funtional piece of gear.
I agree, I wouldn't rewire, so small nuts are definately shot when the wires are, bigger ones can be saved if you don't mind the lower ergonomics of not having a stiff wire but the OP asked about hexes. And as you stated you have done it yourself... Well... The OP has her answer (as in sod the wired hexes, sling them with cordalette) and we agree on the other points, good night I guess? :p
I have hexes that can only fit 3mm accessory cord. REI has 3mm cord rated at 2.8kn. That's a little over 600lbs. That's fine to yell take on and hang but I wouldn't want to take a fall on that. The dyneema everyone suggests is 5.5mm is there 3mm?
And where would one be able to get their hexes or nuts re-wired? Please just answer where you could get it done. I've read the lecture above and know I'm going to hell if I do it.
if they were mine, and the cables were really shot & I had to replace them, I wouldn't have any concerns with drilling them out to fit 6 millimeter cord, but I would round all the edges and deburr the crap out of them.