The autopilot harness for the TruTrak unit was too long so I decided to shorten the cable bundle and reterminate it. I began by identifying each wire and the port in the DB25 connector where it was terminated. Once all the wires were labeled I cut the bundle to the new length. It was then just a matter of crimping new sockets onto each wire and reassembling the connector.
The next task was to begin terminating the intercom wires. I began by terminating the pilot and copilot's auxiliary audio cables in a molex connector. The connector will accommodate twelve pins but only nine will be required for this application. The cables from each crew position are 3-conductor with shielding. I used a solder sleeve with pigtail to attach the shield and one internal conductor to a pin. The other two conductors were terminated with a pin each. That's six pins. I then ran a short length of the same cable terminated in the same manner from the molex connector to the intercom. The molex connector will be attached to its mate which will have the nine wires going to a 3PDT mini toggle switch in the instrument panel. The switch will allow me to select aux audio from either the front or rear cockpit. The switch also has an OFF setting that routes no input to the intercom.
Finally, I cut the intercom wires to length and installed three solder sleeves. I had to stop at this point and order some additional solder sleeves and miscellaneous electrical items to complete the task.
