Panel Overhaul - Part II

After removing all of the old wiring and sensors, it was time to start installing the new wiring.  I followed the guidance of two very knowledgeable authorities when it comes to wiring, Bob Nuckolls, and the FAA with "AeroElectric Connection" and "AC 43-13.1b" respectively.  Coming from the automotive world where everything is shrouded in heat shrink, potting, and boots, I have really come to appreciate aircraft wiring.  All aircraft wire is white (labeled at both ends), and all wiring bundles are constrained with waxed nylon lacing and adel clamps for complete serviceability.  

I started with the engine sensors. You can see the black nylon lacing around the wiring, and the black silicone tape around the engine mount wherever there are tie wraps. Every connection has a strain relief loop, but is well supported to combat fatigue from vibration.

This is the forest of tabs that provides the grounds for all of the components. The tabs have been riveted to the brass strip, but still need solder for a solid electrical connection.

Many of the sensors need custom mounting solutions, such as this fuel flow sensor.  I machined a split clamp out of 6061-T6 aluminum.  After it is mounted, insulation is installed to prevent the fuel from vaporizing.  

After the wiring is run, it is labeled, cut to length, crimped with a pin or socket, and inserted in the connector shell.  After all of the wires for a single connector have been run, the shields (green wires) can be grounded, the shell closed, and the wiring bundle laced for a secure trouble free connection.  

Here is a view of the back of the GNS530. The red silicone tape provides a nice cushion for the strain relief clamp. The green wires are the shields that terminate to the chassis of avionics. The blue solder sleeves are splices for power/ground/ or signal. When running each and every wire, I like to imagine it constrained with just enough support to keep it from vibrating, but not enough to create tension on the connection.

Tools of the trade...

All of the toggle with and circuit breaker wiring is run long and labeled with masking tape and a Sharpie.

As the connectors start to be assembled, the wiring cleans up nicely.

The switches in the center console are given generous strain relief loops.

The remote COM is all tidied up with proper strain relief and support. The rogue wire is the bonding strap to ensure the chassis is grounded.

Wiring to the bus bars and circuit breakers. Power goes in through the large 4AWG wire, through the copper bus bars and circuit breakers, and out the small wires.

All of the ground wires terminate at the brass "forest of tabs". I left a few extra taps just in case I add anything in the future.

It's starting to look like a cockpit again!