I experimented with a wiring idea for the flap circuits today. The flaps have four 18 AWG wires that run back to the actuator and control box (Showplanes FPS). They have to pass up thru the floor or perhaps up thru the floor and a bulkhead depending upon how the routing is done. I really don't want to cut wires if I ever have to take the floor out so I am looking for a way to run the wires with quick disconnects so the wire can just be pulled back thru the grommet or snap bushing (and reinserted when reinstalling the floor). Molex connectors are too big to pass thru a grommet without removing the plastic shell and that can be a pain even with a tool.
What I am considering is just using the pins and sockets from a Molex connector without the shell. You can see below a socket crimped on the end of a wire with heat shrink completely covering it. The other wire has a male pin crimped on and is partially covered with heat shrink. The second picture shows the two wires joined. They are snug but if there is any worry about an inadvertent disconnect, a third piece of heat shrink could be used to encase the joint. Of course, you would have to remove the joint piece with a razor blade to unplug the wires.
Anyway, the connectors add very little to the diameter of the wire and should easy slip in and out of a grommet or snap bushing. I thiink this will be my approach to the flap wiring.
