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Dave's RV-7A Builder's Log
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Date:  4-24-2016
Number of Hours:  4.00
Manual Reference:  
Brief Description:  Autopilot servo wiring

Today’s session was all about fusible links, chafe protection and strain relief. The former topic is probably of little interest to the general public, but the latter two we all have in common. Either way, all are of great importance at this point in the build. After running the pitch servo wires yesterday, it was time to fabricate the 9-pin connector that attaches to the servo. I had used the last of my flexible nylon sleeving to cover the wires (love that stuff, more on order) to provide chafe protection, and after trimming to about an inch from the connector, slipped a couple of pieces of heat shrink (love that stuff too) over the end and then attached the eight D-Sub pins and inserted into the receptacle. After getting everything in place, I slipped the heat shrink back in final position, did the magic shrinking thing and made a nice tidy bundle.

After completing that, I started working back up front to solve a dual challenge—brace the sub panel cut out and provide a convenient place to attach Adel clamps for wire support and strain relief. As luck would have it, I had two pieces of 1/8” x 3/4” x 3/4” angle that I had scrapped years ago during fabrication of a fuselage bracket…both were exactly the same size, and a perfect fit for the openings. After modifying them to clear a bolt, I drilled them to the panel, primed and installed them. The second picture shows the left bracket in place—the right bracket looks similar, but also has an attach point where the RG-400 cable will come through to the panel.

Finally, I fabricated two fusible links to attach the ammeter leads to the shunt on the firewall. These things are stone simple—a piece of AWG 24 wire in a fiberglass sleeve—and are designed to burn up in the event of an overcurrent. The idea is that the AWG 22 wires running through the firewall won’t become electrical fire hazards should those lines ever short…the smaller wire, contained in a protective sleeve will fry first. Productive day…now go eat your fiber.
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Yes FAA, that is my hand...

Yes FAA, that is my hand...

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Bracket for subpanel cutout

Bracket for subpanel cutout

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A fusible link...

A fusible link...

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