Ignition Module Wires, Repair Advice

[jrevens]

#3 solder.

Butt connectors have no place in an airplane.

While I'm not a particular fan of butt connectors in general, there is absolutely nothing wrong with using properly sized, good quality ones (AMP, T&B, etc.) on an airplane, IMHO. It's best to use the ones that crimp & hold the wire insulation as well as the wire, for strain relief and support. They need to be installed with the proper tool. This type of electrical connection is used on a large percentage of factory-built as well as homebuilt aircraft, of all kinds, for wire terminal ends, Faston connectors, butt/splice connectors, etc.

I do personally like soldered connections, well-made, and using adhesive-lined heat shrink tubing to seal and stiffen the joint for a small distance, to prevent flexing at the solder-stiffened wire joint.

The key with the Rotax ignition modules is to keep the wires that exit the modules from flexing/moving in relation to the modules for a distance before allowing a small, reasonable amount of flexing as necessary.

[RF47]

Thanks everyone, appreciate the input! I ended up buying two new modules from Allistair. I will also redo the wiring on my old Ducati modules to keep as a backup set. I'm lucky enough to live down the road from Rotech, so I went and talked to them about repairing the modules. Once I get it all complete, which will likely take a while, I'll try and post a couple pics in the event it can help someone else out. Thanks!

[atosrider]

This topic caught my interest, and the timing was good for ordering new modules during the rebuild of my 912UL powered K3. I did not suspect damaged wiring at the connectors, but they are almost 30 years old now so why not refresh.


While trying to get up to speed on ignition system refurbishing, it occurred to me that the potential vibration loading on the 100hp on straight floats would be far greater than an 80hp on wheels. There are no brakes on floats, and the 100hp wants to idle higher. So, maybe this exercise was not required – oh well, it will feel nicer to be up there with newer equipment.