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Dave's RV-7A Builder's Log
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Date: 6-13-2015
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Number of Hours: 6.00
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Manual Reference:
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Brief Description: Wire harness splicing
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The goal for today was to finish the wire splicing and get the avionics harness ready for installation in the aircraft. When I finished up last session, I still had the GTN 625 wires left to splice. These wires were added when I switched from a GNS 400, so they go to a couple of different places—two go to the audio panel, and three go to the PFD, so more wire tie cutting was necessary to open these bundles up. Once that was done I started working on cutting, stripping and soldering the pins on. Garmin really likes to use miniature D-Sub pins, and that the only tool that will crimp these is the $375+ MilSpec crimper that I don’t have…so, soldering is my only option.
The challenge is that these pins are so small that even tinning the wires makes it almost impossible to slip the pin on, so I adopted a method where I put the pin on, added just enough solder to wet the wire, and then kept it melted while I pushed the pin in place. Every pin got the pull test, and all passed, but a couple of the pins going into the audio panel weren’t up to my standards, so I worked a little more to get them as good as I could. One down side to having wire bundles pre-fabricated is that there isn’t much to work with if you make a mistake and cut something too short, so cutting off the “bad” pins wasn’t really an option, but I got it done.
After spending a little time organizing the bundles, I went back and ran continuity checks on all of the connectors and all passed. With that done, I finished up some odds and ends and called it a day.
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Serial line from GTN 625
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Splicing the GTN 625 into the PFD
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Harness spliced and ready for installation
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