Project: TerryS     -     Entry

Apr 13, 2022 20 Wire Bundles pt.2 Category: Avionics
All the G3x grounds were too short for where I had the forrest of tabs. Easier to relocate that than splice all this ground wires. While I was at it, I added a second one on the other side of the rib, just because I already had it.

I also started installing breakers and made the buss straps out of brass that I got from B&C just fo that purpose. I'm not super happy with how the came out. I'm going to B&C in a couple of days to pick up some stuff and I'm going to grab some more brass stock and remake these. If you look at the picture below, the 90* angle on the right of those strips is where a jumper will bolt to tie them all together. As of right now, thats only about 3/4" away from the MFD. If I remake these, I can get another 1/4" or so of clearance, and since it's only $6 worth of brass, I'm going to do that.

The prefab wire bundle has the stuff that runs aft coming off the corners of the main trunk, as if Levi planned for it to come down the outside bulkheads where the fuel vent lines run. I called him and he said that I could either do it like that or I could go fwd to the firewall per one of Vans plans.

If I go down the vertical, I'd have to secure part of the run to the fuel vent line where the rudder cable runs by to prevent any possibility of chafing. Levi said that's what they do when then have to run wires there. I tried it per his suggestion, with double wrap of silicone tape on the vent line wherever I used a wire tie and decided I couldn't live with that as a practice if there were absolutely any other possibility.

The concern with routing fwd and then down the firewall was that it was going to eat up a couple of extra feet of can bus and it's not like you can just butt splice that stuff. He cautioned me that length would be the limitation.

I got out a tape measure and after a lot of back and forth, determined that it would work. I didn't want to do a lot of trial fitting, since the can-bus legs that run aft both have branches coming off them (ELT, roll trim roll servo, pitch servo, magnetometer) and they are so fat that they won't fit through a 5/8" hole with the grommet in. (FYI- after the fact, I split snap bushings and popped them into the holes where appropriate).

In fact, to get them to squeeze through there at all, I had to remove some silicone tape and shrink wrap that the fabricator had applied, and wrap a couple of areas tight with blue 3M tape to get them through at all.

The more I play with this the more chance for damage to the bundle, hence all the pondering and measuring.

So anyway, after 2.5 days and about 20 hours including phone calls, VAF research and a bunch of trial and error, here's where we are. Bundle is in with legs routed to appropriate locations.

Making progress.


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