Marcel,
There is no easy solution, but I have had the luxury of wiring a number of
new aircraft and rewiring a number of older aircraft.
Since your airplane is used you can either live with what the previous buil
der did, rewire, or patch.
If it isn=92t broke and you are going to patch, follow these rules:
1. Make sure the com/transponder/vhf nav antenna wires are clear of the
com and any current carrying wires.
2. Shield all the intercom and radio wires you can. Power and ground ar
e not shielded normally.
3. Since it is a patch job, clearly mark all the wires using permanent m
arking ties. (A zip tie thingy with a tab.)
4. Make sure you have adequate access to the center tunnel hole as fuel,
brake, and wires are present and by adjusting the position of much of this
you may cause a brake line leak, fuel line cut etc. Make a new access hol
e if necessary. I have one large belly panel and a smaller one at the rear
.
5. Most rewire jobs are hampered by the wires running like a spider web
all over the place. Simply pull what you can, mark, lay out and deconflict
the wires. Mark them well. If the run is too short to put it where you w
ant it, you may be better served by making a new wire loom. If not, cut th
e wires and put in a circular or similar plug that is appropriate to make a
n extension. If you don=92t know how to properly crimp and solder=85Practi
ce, buy the right tools and learn the skill.
6. The sticks, autopilot servos, flaps, fuel pump, fuel flow sensors, et
c. will run wires in many directions in the tunnel. Most previously wired
airplanes were wired on the fly rather than in bundles with neat runs comin
g off the bundle. To straighten out the spaghetti, you may have to disasse
mble plugs, and restring the wire. This is tedious, and many hours of mark
ing wires, pins and breaking pins trying to remove them will ensue. Someti
mes it is best to just leave it like spaghetti, but well marked and where p
ossible, bundled. Often it is best to simply group wires into multiple bun
dles and just live with it. It looks messy, but it works. See below.
[cid:image003.jpg@01D45DA4.F34C2360]
1. Plan your panel to airframe interface now. If a panel is not easily
serviceable it will not get serviced.
* The panel and its center support if used should be on nutplates th
rough the firewall for ease of removal.
* If wires run through a hole into the center base of the panel, put
in both strain relief, grommet or smooth casing through the tunnel, bend y
our wire bundle to allow room for the panel to have the wires come up to th
e panel without chafing, interfering with components or restricting install
ation or removal of the panel.
[cid:image007.jpg@01D45DA4.F34C2360]
* I like to make a series of junction plugs. One of mine has a junc
tion plug right where the wire bundle comes out of the tunnel hole. Then a
jumper bundle moves over to my firewall penetration hole (covered by a sta
inless plate and reinforced for shear strength).
* Making the face plates of the panel of FRP (Fiberglass Reinforced
Plastic) as it is easy to fix small oopses, easily painted, easy to cut, an
d very strong. Metal is fine, just don=92t make an error.
1. Plan your firewall penetration for ease of disconnect.
[cid:image008.jpg@01D45DA4.F34C2360]
1. Lay out your panel ergonomically. Use a smooth flow with switches an
d instruments grouped by function or live with what the previous owner stuc
k you with.
2. If radios are in the rear heat in the panel is reduced unless you hav
e an older Dynon or similar EFIS. Heat will build rapidly in the panel. P
lan cooling fans if necessary.
3. Create drawings and take pictures to document what you have done.
4. Label you plugs and the wires in them for troubleshooting.
5. Make up a wiring book because I guarantee in a couple months you will
forget.
Contact me off line as I am putting together a second hand panel with its d
ocumentation. I can send examples for documentation.
Best Regards,
Bud Yerly
Custom Flight Creations
Sent from Mail<https://go.microsoft.com/fwlink/?LinkId=550986> for Window
s 10
________________________________
From: owner-europa-list-server@matronics.com <owner-europa-list-server@matr
onics.com> on behalf of zwakie <mz@cariama.nl>
Sent: Saturday, October 6, 2018 4:38:27 PM
Subject: Europa-List: Advise wanted: route new wire bundle through tunnel
I'm in the process of installing a new panel with a.o. a TRIG TY91 radio an
d TRIG TT21 transponder with remote control heads.
The radio units have been installed on a tray under the baggage area, and I
am now wondering what the easiest way is to route the wire bundles for tho
se forward to the instrument panel.
To my dislike the builder has routed most electrical wires as well as fuel
lines through the tunnel, but I am going to leave that for now. This howeve
r makes the tunnel an already 'busy place', and I do not want to create pro
blems with existing wires and lines so I need to be careful when routing th
e new wire bundles.
Routing the bundles across the bottom floor and then work them upwards to t
he top of the tunnel (which is my preferred position, above the fuel ilnes)
is going to be a problem as a number of wires/lines is running from port t
o starboard, effectively making this approach impossible.
Another idea I had was to use some sort of flexible 'pipe' with 2" diameter
, and work that through the tunnel first to use is as a guide to pull the b
undles through. Problem with this approach however is that it will be hard
to properly connect the bundle to the top of the tunnel. Additional trouble
factor is that the DB connectors for the control heads is of the fixed typ
e that cannot be opened up to allow for a smaller diameter.
Any suggestions for others options to pull this off? I appreciate all the a
dvise I can get.
--------
Marcel Zwakenberg
XS TG || 912ULS || PH-SBR
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