Services

With over 20 crimpers I can terminate wire sizes 24 AWG thru 2 AWG using MIL-C-27500 shielded Tefzel and MIL-C-22759 unshielded Tefzel wire.  AMP PIDG nylon insulated terminals are used for sizes smaller than 8 AWG‚ with MS-20659 and AMP Solistrand lugs for large power wires.  To improve durability, I apply TYCO epoxy lined heat shrink for insulation support.  Shields are terminated with polyvinylidene fluoride Raychem S01-0X-R solder sleeves.  MS-25171 boots protect terminal posts.  Techflex fiberglass sleeve installed over alternator and starter cables is a cost-effective way to resist heat damage to cables routed under the engine and exhaust tubes.   

The harnesses on my SALE page are examples of capability.  Contact me for any type of shielded and unshielded wire replacement.  Keep in mind some factory manuals do not include wire length.  Customers may ship wiring for duplication or provide measurements.

Periodic crimper service checks performed with a Mitutoyo 342-271 crimp depth micrometer and go/nogo gauges.


Wire manufacturer certification available on PDF.

Radio Harnesses

I have built and installed complete radio stacks for local shops, but no longer have the time for large installations.  Fabricating harnesses for used avionics considered on a case by case basis providing the owner sends the factory backplate with associated connector and backshell.  There is no reason to buy used avionics without the tray and connector assembly.  


There will be an additional charge for crimp type D-Sub connectors and MIL-SPEC contacts if your installation kit has solder type connectors. 25 position crimp type D-Sub connectors typically cost less than $1 with contacts under $.60 each.


Buyer Beware: Garmin does not sell their threaded backshell retainer separately.  This is due to customers buying installation kits for competitor slide in replacements of Garmin units.  ITT Cannon M85049/48 style backshells were designed to be attached from the outside.  Garmin's threaded backshell retainer is proprietary and manufactured for Garmin connector screws to attach from inside the trays.  If you buy used Garmin avionics, make sure the seller sends all associated connectors and mounting hardware. 

Upgrades

Alternator Cable Upsize

Adding a higher output alternator or new panel with additional electronics?  Most later model 172's and 182's use an 8 AWG shielded cable to supply voltage from the alternator to the bus.  If you're increasing power requirements, consider going up 1 size to 6 AWG shielded.  Pricing available on my sale page. 

Alternator Warning Indicator

Consider the high quality indicator MS25041-6 with 14v GE330 or 28v GE327 bulbs.  If you're adding a Plane Power R1224B with an indicator, you need to understand how the O/V lamp circuit differs from the Cessna diagram

Field Switch

Early model master switches turned on the battery and voltage regulator together.  This left no option for the pilot to shut off an over voltage generator without shutting off the battery.  These old switches can be a push/pull or solid rocker.  Later Cessna introduced the over voltage cutout sensor with split rocker master switch.  The new split switch allows the alternator to be switched off and battery remain on.  This gives the pilot the ability to manually remove power from the regulator, effectively shutting off the alternator during an over voltage condition.  It's redundancy in case the over voltage sensor fails to do it's job.

One customer added a 5 AMP Klixon push/pull "FIELD" circuit breaker for his new voltage regulator.  Another solution to consider is a TYCO switch/breaker W31X2M1G5.

Accidents Happen

This connector was damaged from a short at the battery switch.  New wiring for mag P leads, starter relay, battery relay and flaps allowed the owner to delete the connector and reduce clutter behind the  breaker panel.  The owner wisely used this opportunity to replace other cables while his Cessna was out of service.

I can build your circuit breaker panel with original series AMP connectors used by Cessna, or delete them for a more sanitary installation.   If you want 100% originality it's best to send me your harness for duplication.