Ignition Module Wires, Repair Advice

[4Hummer]

#3 solder.

Butt connectors have no place in an airplane.

[RF47]

Thanks for the quick reply 4Hummer. I think you are right, a solid lineman's splice with minimal solder, coupled with good fixation of the wires to avoid movement should be plenty strong. Thanks! Anyone else care to chime in, or have experience fixing this?

[109JB]

https://www.amazon.com/TICONN-Connec...dDbGljaz10cnVl

[RF47]

Thanks John. This is a bit of a silly question, but do you think there is any chance the low melting-point solder in these type of connectors (~115C) would get anywhere near hot enough to re-melt while running?

[109JB]

Thanks John. This is a bit of a silly question, but do you think there is any chance the low melting-point solder in these type of connectors (~115C) would get anywhere near hot enough to re-melt while running?

According to the specs, it takes 280 deg F to melt the solder. I would not be worried.

[avidflyer]

I bought one of those modules from Allistare Wilson. I tried it on the 912 UL, and it worked fine. Ended up not needing it and so it's in a drawer waiting till I install the ULS and I will use it on that engine cause it has a soft start module built into it. I would not hesitated to get another one if needed. I also moved my modules to the firewall side of the motor mount to avoid broken wires in the future. If I was you, I would maybe fix both modules you have, install one of the aftermarket ones, and have a spare Rotax one if you ever need it. JImChuk

[WWhunter]

I bought one of those modules from Allistare Wilson. I tried it on the 912 UL, and it worked fine. Ended up not needing it and so it's in a drawer waiting till I install the ULS and I will use it on that engine cause it has a soft start module built into it. I would not hesitated to get another one if needed. I also moved my modules to the firewall side of the motor mount to avoid broken wires in the future. If I was you, I would maybe fix both modules you have, install one of the aftermarket ones, and have a spare Rotax one if you ever need it. JImChuk

As Jim mention, probably a good idea to have a spare. I had a persistent issue with my modules several years ago. Substandard wire in them (in my opinion). Several areas of the wires broken inside of the insulation. I had to cut/spice/repair several sections of my modules and wires from the stator.

Granted I come from experience in building military grade electronical test equipment for fighter aircraft, so was used to using very high quality wires. The wire that Rotax (ducati) uses is pure junk!

[jrevens]

Thanks John. This is a bit of a silly question, but do you think there is any chance the low melting-point solder in these type of connectors (~115C) would get anywhere near hot enough to re-melt while running?

Not at all silly… as John B. said, it shouldn’t be a problem. However, “solder sleeves” have gotten mixed reviews from people. Bob Nuckolls was (is?) a fan, but then noted some problems with them…. incomplete or poor flow of the solder into the wire for one thing, I believe. I think variable quality may be an issue, like with so many things made in China especially. That’s just my personal opinion and experience.

[Rodney]

Just put on a new set of modules from Alistair Wilson. They are really well made and he was a pleasure to deal with.

My engine just would not run on the "A" side of the ignition. I traced everything I could; You have to understand I'm very limited
when it comes to electronics.

What I eventually found really surprised me. I had four bad spark plugs - all on the A side. I've never had that happen before.
I replaced all the NGK spark plugs with Champions and my engine is running fine. The reason I went with Champions is that I live in
a small community and that was all I could get. Even had to go to two parts stores to get a collection of 8 plugs.

Still - I like the modules I got from Alistair - very easy to install and I moved them away from being on top of the engine.

Regards
Rodney

[Maverick]

What is the concept of "Soft Start"? I've seen it referenced but, I don't really know what it is. Would someone care to edify me?
Maverick