Brief Description: Wired main power distribution and ground
Since the last time in the shop I've done quite a bit of planning and placed a sizeable order of parts to keep the wiring project moving forward. One thing I concluded was that the 2 AWG main wire from contactor to firewall was more than required for the job. To cut down on weight, and to have a chance to do better lug soldering than the first time, I pulled out the old and replaced it with 4 AWG wire. Another problem I identified from my previous efforts was that the battery settled down too far in the battery box. I removed the box, put two layers of rubber baffle material in the bottom and reinstalled. The reason this was so critical is that the main ground and positive cables would have rubbed on the box had I not corrected it. That would surely have invited a short circuit in the future. I mounted the Required (always on) Buss and connected it to the input side of the battery contactor. Finally I made an extruded bracket for my local ground which was secured with the same bolts that hold the flap control bearing in place. Once I made the positive and ground connections, I checked for continuity on all circuits and even tested the battery contactor by running a jumper from the contactor ground stud to ground. Voila, a completed circuit to the firewall. BTW, the black cables from the battery were pre-fabricated to my specs by B & C Specialty Products out of 4 AWG welding cable. That is because welding cable is much more flexible that regular aviation wire.