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Larry Winger's 601XL Project
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Date: 8-4-2012
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Number of Hours: 2.75
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Manual Reference:
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Brief Description: 1 - Rewired fuel pumps
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If you've been following my project, you know that I've built at least 1.5 airplanes in the process of building just one. Rarely do I make a part or complete an assembly without some form of tweaking or rework. Today was no exception. In yesterday's session, I was using inline butt connectors to mate the fuel pump leads (red) to my power wires (white). I was also doing it one-handed while standing on my head on the cockpit side of the firewall. This left me with no small amount of uncertainty about the integrity of those crimps. "Good enough" is not good enough when building an airplane, especially when dealing with something as critical as delivery of power to the fuel pumps. Sooo, I woke up determined to fix the situation. In each case, I retracted the wires back onto the engine side of the firewall where I could get a better working angle. In the case of the secondary pump, I made a soldered overlap splice using Bob Nuckoll's technique of wrapping on single strand left one inch longer around the overlapping wires before soldering. I covered it with heat shrink and pulled it back through the firewall to the cockpit side. BTW, the connection is actually inside the Adel clamp you see in photo #1. With the primary pump, I pulled all the connections to the engine side where I completed them and left them. In this case I used a butt connector (no junior high jokes, please) that I protected with heat shrink and then immobilized it by rescue taping it to the carb fuel line. It took 2 hours and 45 minutes to buy back my peace of mind. Well worth the investment.
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New wiring with routing through clamp
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Old wiring. It might have worked, but who wants to take that risk?
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Inline butt connector with heat shrink, immobilized against fuel line to carb
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