Abstract: Methods and apparatus are disclosed for continuous-line fabrication of helically wound spirals of desired cross-sectional configuration, such as planar surface spirals, for assembly into conveyor belts. In-line wire shaping and handling procedures and apparatus enable consistently reliable production of uniformly shaped spirals at commercial production rates. Round wire from unsupported coils is shaped in line and controlled as directed to a winding mandrel. Orientation of the shaped wire about its central longitudinal axis, winding tension control, presetting a longitudinal camber in the shaped wire, and wire shaping control are used to compensate for changes in mechanical characteristics of the wire or wire diameter, which occur along the length of a coil, without affecting established winding machine parameters such as lead-in angle for the wire or longitudinal location along the mandrel for starting helical winding.