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Services
With over 25 crimpers I can terminate wire sizes 30 AWG up thru 2/0 AWG into most General Aviation and transportation industry interconnects including Burndy, TYCO, AMPHENOL, Weather Pack, Metri-Pack and Sumitomo. I use FAA recommended MIL-C-27500 shielded Tefzel and MIL-C-22759 unshielded Tefzel wire for all airframe and avionics harnesses. New for 2022 I’ll be using Burndy YAV series lugs on all wire sizes exposed to the elements due to durability and sealability. AMP PIDG nylon insulated terminals are acceptable inside the cabin for sizes smaller than 8 AWG and AMP Solistrand lugs for large power wires. To improve durability for uninsulated lugs, I apply TYCO fire retardant 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.
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.
Push/Pull Switch
Early model Cessna push/pull master switch 0713026-5 turned on the battery solenoid and voltage regulator together. This left no option for the pilot to shut off an over voltage generator/alternator without shutting off the battery. Prior to the split rocker, some models used a solid rocker switch. 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 should the sensor fail.
Service Bulletin SEB93-15 provides switches MS24524-22 and MS27407-1 for replacing various push/pull switches now obsolete. Both have mounting thread pitch of 15/32-32 which a number of companies make dress nuts.
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.
Past Projects
