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Dave's RV-7A Builder's Log
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Date: 3-12-2016
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Number of Hours: 2.50
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Manual Reference:
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Brief Description: Main power supply
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I started the firewall forward wiring by diving into the fabrication of the 6 AWG supply lines feeding the main power bus. After doing significant research and planning, I had elected to upgrade from the 8 AWG lines supplied years ago when I purchased the basic wiring bundle. Although the 8 AWG wires called out in Van’s plans would technically be sufficient to handle the load, I felt that 6 AWG would be more suitable. After physically attaching the main components last session, today I started running the wires from the alternator to the ammeter shunt, then through the ANL current limiter base to the hot terminal on the starter relay.
In order to gain access to the relay, I had to remove the battery relay, which in turn required me to remove the battery box. With the battery box off, I had good access to the top of the relays and was able to get the system disassembled fairly quickly. Wiring has made me feel like I’m going backwards as it often requires me to remove things that had been “permanently” installed. With everything now open, I started wire fabrication. 6 AWG wire is probably more suitably called cable, as it is ¼” thick and cannot be easily maneuvered—making exact connection of the terminals very important. To ensure I did it correctly I used a sharpie to mark a “clock” position on end and then took the assembly to the manual crimper I had purchased from B & C. That worked really well, and after putting the ends into a vise and putting all of my weight into it, ensured that I had a good connection.
The whole process took a couple of hours, but when I was done I had almost all of the main power wiring complete. Next steps are to physically locate the two fuse blocks and main power bus behind the panel (for easy access when needed) and then run those wires to complete the main power assembly. I ordered a different bus that would be more suitable for my needs and will have to wait for that to arrive before settling on a final location.
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First 6AWG line fabricated
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Basic wiring complete
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Battery box removed for access
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