Title: Fuel sender wiring
Over the last couple of days I cleaned up some wiring including routing and securing the fuel sender wires and the wire bundles where they route laterally in front of the spar in close proximity to the fuel lines. The capacitance fuel senders require power ground and sense wires, which are all in a shielded twisted triple, but in this instance the braided shield isn't utilized. The wire is routed through a standard outboard passthrough grommet in the fwd 1/2 of the spar box, then go outboard in front of the spar web. I glued a strip of caterpillar grommet on the sharp skin edge, sleeved the wire in snakeskin abrasion protection, and of course it also has the braided sleeve under the insulation, so it's quite well protected from abrasion. Where it makes the bend around the skin edge, it's held in place by a dab of RTV, then a couple of wire tie mounts glued to the skin with E6000. Even if the E6000 give out at some point in the future, it cant really flop around into anything important because in true belt and suspenders fashion, I also stood it off if the fuel vent line with a couple of adel clamps. In the cabin, the wire runs that run laterally in front of the spars are segregated from the fuel lines by adel clamps. Per print and industry standard, the wire run are above the fuel lines, but when they get to the sides of the cockpit area you are forced to transition them lower because thats where the spar grommet is located. This caused me some difficulty because I've got a lot of wires in these bundles plus pitot and AOA lines, all of which have to fit under kick panels but still have to be separated from the fuel lines. I played with this for a while and tried a few different solutions before deciding that none of them were as bulletproof as just using adel clamps carefully positioned to firmly securing everything so that there was no chance of chafing against a fuel line or the kick panels that will eventually cover all this up. You can't really tell in the pictures, but where the wire bundles cross over the fuel lines there is about 1/2" separation. This is the bare minimum for wires and fluid lines. It would have been a lot easier if vans had designed this differently, but at this point I've got this area rock solid with zero chance of anything getting together that shouldn't.


NOTE: This information is strictly used for the EAA Builders Log project within the EAA organization.     -     Policy     -     © Copyright 2024 Brevard Web Pro, Inc.