Wires

[Flybyjim]

This will be my third plane that I will have built and the other two have been fun to build but I have never been satisfied with the wiring. No matter how much I plan it seems I have a mess. What are good sources for this problem

[DesertFox4]

Jim - maybe some will share photos of their behind panel wiring layouts to show how routing and planning can clean up the wiring installation.

I love a cleanly wired panel and hope to do much better on my 7SS than I did on my 4 although my model 4 has worked flawlessly. Some of the builders on here are over the top skilled at wiring including the factory built Kitfoxs.

[akarmy]

Hi Jim,

Check out the pictures I have posted of my Series 7 at this link.

Wiring pictures gallery



You didn't say where your questions are?

I used only aircraft tefzl wire, tried to support it at any location where it can rub on structure. Label each wire so you know where it goes if you have to troubleshoot it later. I used an automotive blade fuse block to make power distribution easy. Then just wired it up one wire at a time. I used black zip ties to hold everything in place. Just put them on loose at first, then cut them off if you get too many wires going through a location. When you are done you can put new zip ties on to secure the bundles or on my current project I went back and laced the wires with waxed string to replace the zip ties.

If you have other questions ask away. Good luck with your project!

[DesertFox4]

Nice work Andy.

[Flybyjim]

Yes,
Looks good, For simple aircraft there just seems to be a lot of wires!

[n85ae]

I used to do this for a living, the secret is VERY simple, but NOT many people
seem to understand the concept.

I use old copper house wire to make temporary bundle guides (like fishing rod
line guides), where the bundles should logically go. These are used to rough
route the wires.

Basically the key is to route wires first, cut them long (2-4 inches) but NOT
connect them. Then using masking tape, wire, string, etc. Make everything
look like you want. Tie it down, I use Adel clamps to connect to the airframe,
and waxed dacron lacing tape to bundle the wires. After the bundles are then
nice and neat. THEN terminate the ends and hook up the gear.

DO NOT hook up wires, and try to string them one by one, you will just end
up with a big mess. This is how most people make a mess in my opinion.

Regards,
Jeff Hays

[t j]

Get a hard copy of AC 43.13-1B

"Chapter 11. Electrical Systems
ON line here http://www.aeroelectric.com/Referenc...Electrical.pdf

Look through all 12 sections in this chapter. Everything about proper aircraft wiring techniques is in there. You will be surprised at the good information and probably important things you didn't know about wiring an aircraft.

My favorite sections:
Section 10. Service Loop harnesses

Section 11. Clamping

Section 12. Wire Insulation and lacing String Tie
I have been progressively replacing the plastic zip ties in my wiring with wire lacing string. It takes longer to install but is much nicer in my opinion. I can reach behind the panel without drawing blood now.

[War Eagle]

Hi Jim,

I used only aircraft tefzl wire, tried to support it at any location where it can rub on structure. Label each wire so you know where it goes if you have to troubleshoot it later. I used an automotive blade fuse block to make power distribution easy. Then just wired it up one wire at a time. I used black zip ties to hold everything in place. Just put them on loose at first, then cut them off if you get too many wires going through a location. When you are done you can put new zip ties on to secure the bundles or on my current project I went back and laced the wires with waxed string to replace the zip ties.

This is what I did also. I labeled each end of the wire using white shrink tube and wrote the name and polarity on it with a fine point permanent felt tip marker and then I would heat shrink the tubing. The label is very nice looking, won't tear off and can be very easily read when needing to do trouble shooting.

[n85ae]

The irony is that the more careful you are to label everything, you will likely do
such a good job wiring, that you will never have the need to troubleshoot
anything ...

Jeff

[Dave S]

"you will never have the need to troubleshoot
anything ..."

Jeff - I think we can live with that!

Dave S