Brief Description: Wiring - Control Sticks & Headset Jacks
It was one of those days where you spend a lot of time in the garage but doesn't look like much got done. Started the day with intentions of installing the LH headset jack module. The first thing that was noticed was that the aft hole in the seat pan was smaller than the forward hole. There was no way that the step in the isolating washer was going to go through the hole. So, sanded down the shoulder to the point that essentially had a flat isolating washer. Installed both jacks (shouldered isolating washer on the front jack) and then checked for continuity between the nut and airframe. Now I know why they call it an isolating washer - had continuity on the aft jack with the smaller hole. Obviously the jack was making contact with the seat pan. There was not enough room using a regular drill to enlarge the hole so ended up buying a close quarters drill from Harbor Freight. Enlarged the aft hole (both sides of the aircraft) to 1/2" and then reinstalled the jacks with shouldered isolating washers and checked for continuity. No continuity which is good but now I'm one isolating washer short for the other side. Still waiting for auxiliary audio jack parts but will need to find another isolating washer before installing the RH side jacks. No part number that I can find. Finally, drilled the 1/4" hole on RH side for the auxiliary audio jack. (page 31B-17, steps 2 through 5 - LH side only, and step 6).
Pressed on with pulling wires through control sticks. What could possibly go wrong since I had already pulled strings that were just waiting to for wires to be connected and pulled through. First attempt, the string came out with only one wire :(. Long stroy short is it took a couple of hours to fish another wire through before being able to pull the PTT wires through the stick. Amazingly, the second stick was only a couple of minutes behind the first one and was done. Soldered wires supplied with Ray Allen G1 grips to the push button assembly and crimped to PTT wires with butt slices and heat shrink.
