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Dave's RV-7A Builder's Log
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Date:  1-7-2017
Number of Hours:  4.00
Manual Reference:  
Brief Description:  Misc firewall forward work

This part of today’s session was devoted to working on firewall forward to finish up the engine compartment. I started by removing every single Adel clamp securing the spark plug wires and rearranging the whole affair. Like the three attempts at getting fuel lines correct, the third time was a charm with the magneto wires. Previous posts detail the issue with the wires, but the primary challenge is that the upper wires are simply too long and there is no easy way to deal with the excess. Added to that is the fact that my second solution involved attaching Adel clamps to the engine mount and routing the wires a bit more circuitously to take up slack. Most of the information I can find suggests that having the wires leave the magnetos (attached directly to the engine) travel to the engine mount (attached to the aircraft) and then back to the engine potentially introduces unwanted vibration and can cause fatigue failures in the wires over time. Seems bad to me…

My solution was to add Adel clamps on each of the two aft intake tubes and two case bolts to support the lower wires on their way forward. For the upper wires, I routed them across the top of the engine utilizing the same bolts as previously, and then ran them down almost to the opposite magneto before reversing course up to the baffle bracket and then to the spark plugs. A few zip ties will keep everything organized, and now there are no magneto wires supported by anything other than the engine.

I did some general wire tidying and other odds and ends to finish out the session. One note—I will need to redo my exhaust hangar brackets as they are also using the engine mount for support…which creates the same potential for unwanted vibration and cracks. That will be a different day.
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Left side magneto wiring

Left side magneto wiring

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Left side Adel bracket on aft intake tube

Left side Adel bracket on aft intake tube

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