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Kurt Haller RV-9A
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Date:  2-27-2011
Number of Hours:  6.00
Manual Reference:  7
Brief Description:  Wing wiring/aileron bellcrank bolts

Routed wires from conduit to lamps in both wings. Pop riveted plastic tie wrap mount to structure, wrapped wire in silicone fusion tape, then tie-wrapped the wire. (See images of left wing, 1 & 2) Leads to Duckworks lamps are #18, so carefully clipped a few strands of the #14 wire to make it fit in a red butt splice. (See image 3.) Still have to immobilize the wire as it runs from the spar web to the light fixture. The butt splice should be replaced with a knife splice, since the the bulb lead and the bulb are one unit. I'm thinking of replacing with LED lights someday, so this is good enough for now. Made new ground straps for the lamps out of #14 Tefzel and blue ring terminal (also in image 3).

Reworked the aileron bellcrank bolts. The were installed with the nylock nuts on top. Should the nylock ever loosen (unlikely), bolt could fall out. Had to take out the crank and 2 mounting flanges to be able to disassemble. Total of 10 bolts to re-torque upon reinstallation of the 2 cranks. My tube of orange Torq-Seal has dried up, so I marked the bolts/nuts with a sharpie. Need to get a new tube and mark the bellcrank assys properly before closing up the wing.
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#14 wire run from conduit

#14 wire run from conduit

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Close up of pull-riveted tie wrap mount.

Close up of pull-riveted tie wrap mount.

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Butt splice to bulb lead & gnd strap

Butt splice to bulb lead & gnd strap

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