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Kupe's Zodiac 650B
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Date:  7-16-2016
Number of Hours:  1.50
Manual Reference:  
Brief Description:  Elevator Trim Wiring Connections

Began the process of completing the elevator trim wiring by assembling a 9-pin D-sub connector to the end of the cable. Since the aircraft will be moved to a hangar for final assembly (wings and tail section) I'm going with a "quick connect" method for the wiring with functionally organized D-sub connectors to simplify the final assembly somewhat. Today was my first - for the elevator trim servo wiring cable. If anyone cares, I chose D-subs over other methods (Molex, Weatherpack, MIL-spec, et al) because I find them generally easy to work with, well-reinforced, and relatively inexpensive.

So my first of many connections began today with the elevator trim servo cable, which is a standard 5-wire cable commonly used with the Ray Allen servo series. It's a straightforward job to:

- Peel open the cable covering and trim it back
- Strip the ends of the individual wires
- Crimp a pin (of the appropriate gender) onto the end of each wire
- Insert the pins into the housing, feeling/listening for a click as it seats
- Enclose the wires in heat shrink
- Assemble the cover around the housing

First one finished, about 9 more to go.
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Strip each of the 5 wires and attach pins to each one via crimp.

Strip each of the 5 wires and attach pins to each one via crimp.

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Insert pins into plug housing, heat shrink, and begin plug cover assembly.

Insert pins into plug housing, heat shrink, and begin plug cover assembly.

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Finished plug - mail end.

Finished plug - mail end.

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