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Thread: Wires

  1. #1
    Senior Member Flybyjim's Avatar
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    Default Wires

    This will be my third plane that I will have built and the other two have been fun to build but I have never been satisfied with the wiring. No matter how much I plan it seems I have a mess. What are good sources for this problem

  2. #2
    Administrator DesertFox4's Avatar
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    Default Re: Wires

    Jim - maybe some will share photos of their behind panel wiring layouts to show how routing and planning can clean up the wiring installation.

    I love a cleanly wired panel and hope to do much better on my 7SS than I did on my 4 although my model 4 has worked flawlessly. Some of the builders on here are over the top skilled at wiring including the factory built Kitfoxs.


    DesertFox4
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    7 Super Sport
    912 ULS Tri-gear


  3. #3
    Senior Member akarmy's Avatar
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    Default Re: Wires

    Hi Jim,

    Check out the pictures I have posted of my Series 7 at this link.

    Wiring pictures gallery



    You didn't say where your questions are?

    I used only aircraft tefzl wire, tried to support it at any location where it can rub on structure. Label each wire so you know where it goes if you have to troubleshoot it later. I used an automotive blade fuse block to make power distribution easy. Then just wired it up one wire at a time. I used black zip ties to hold everything in place. Just put them on loose at first, then cut them off if you get too many wires going through a location. When you are done you can put new zip ties on to secure the bundles or on my current project I went back and laced the wires with waxed string to replace the zip ties.

    If you have other questions ask away. Good luck with your project!
    Andy Karmy
    Kitfox 7 - 912S - SOLD
    Auburn, WA

    http://kitfoxflying.com

  4. #4
    Administrator DesertFox4's Avatar
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    Default Re: Wires

    Nice work Andy.


    DesertFox4
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  5. #5
    Senior Member Flybyjim's Avatar
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    Default Re: Wires

    Yes,
    Looks good, For simple aircraft there just seems to be a lot of wires!

  6. #6
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    Default Re: Wires

    I used to do this for a living, the secret is VERY simple, but NOT many people
    seem to understand the concept.

    I use old copper house wire to make temporary bundle guides (like fishing rod
    line guides), where the bundles should logically go. These are used to rough
    route the wires.

    Basically the key is to route wires first, cut them long (2-4 inches) but NOT
    connect them. Then using masking tape, wire, string, etc. Make everything
    look like you want. Tie it down, I use Adel clamps to connect to the airframe,
    and waxed dacron lacing tape to bundle the wires. After the bundles are then
    nice and neat. THEN terminate the ends and hook up the gear.

    DO NOT hook up wires, and try to string them one by one, you will just end
    up with a big mess. This is how most people make a mess in my opinion.

    Regards,
    Jeff Hays

  7. #7
    Senior Member t j's Avatar
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    Default Re: Wires

    Get a hard copy of AC 43.13-1B

    "Chapter 11. Electrical Systems
    ON line here http://www.aeroelectric.com/Referenc...Electrical.pdf

    Look through all 12 sections in this chapter. Everything about proper aircraft wiring techniques is in there. You will be surprised at the good information and probably important things you didn't know about wiring an aircraft.

    My favorite sections:
    Section 10. Service Loop harnesses

    Section 11. Clamping

    Section 12. Wire Insulation and lacing String Tie
    I have been progressively replacing the plastic zip ties in my wiring with wire lacing string. It takes longer to install but is much nicer in my opinion. I can reach behind the panel without drawing blood now.
    Tom Jones
    Classic 4 builder

  8. #8
    Administrator DesertFox4's Avatar
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    Default Re: Wires

    Jeff- thanks for the tips. Makes perfect sense.

    Tom- I appreciate the link.


    DesertFox4
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    7 Super Sport
    912 ULS Tri-gear


  9. #9
    Senior Member jiott's Avatar
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    Default Re: Wires

    One thing I found very handy for bundling wires in the longer runs like from the tail cone to the console and the console to the panel was lightweight plastic 1/2" sprinkler pipe (lowest pressure rating like 100 psi I think). I slit the pipe lengthwise to easily get the wire in and out at various points along the run. The slit would close back up and contain the wires quite well. At some points along the run I would put some zip ties around the slit pipe to attach it to the frame and keep the slit closed if needed. I even ran some of my pitot and static tubing inside this pipe. It is really lightweight and gives very good protection to the wires.
    Jim Ott
    Portland, OR
    Kitfox SS7 flying
    Rotax 912ULS

  10. #10
    Administrator DesertFox4's Avatar
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    Default Re: Wires

    Jim, I used that on my model 4 and the 7 SS. Makes running wires from the console to the tail easy. Also great for future wires if needed. Very lightweight.


    DesertFox4
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