Mounted the Dynon pitot tube heater controller and ran the power wire. Grounded with a pop rivet, but I'm redoing all pop rivet grounds following BobNuckolls' advice:
What you're looking for in bringing terminal and airplane together is a GAS TIGHT joint. This is between the terminal face that comes into contact with the aircraft's metallic surface.
This usually means that you've applied enough force to DEFORM irregularities in the two surfaces and literally squash the materials together. This is the same process described in:
If you want a local grounding joint that outlasts the rest of the airplane use 10-32 hardware to bring terminal and airplane together. Brighten up the terminal surface that touches the airplane. Brighten up the airplane that touches the terminal. SMOOTH! and SHINY! don't scuff it up with coarse abrasives.
Make up the joint with the a washer between screw head (or nut) and the opposite side of the terminal. Use metal locknut (MS21042-L3) on the screw.
"Icing on the cake" is to coat one of the mating electrical conduction surfaces with thin layer of silicone grease before mating. Torque to 20 in-lbs.
THAT joint will not spin on the screw . . in fact, you should tear the wire grip off the terminal before the rest of it moves. If you pop-riveted a nav light ground, it would probably be okay but the higher you go in current through the joint the more important it is to get it gas tight. Short of soldering/welding the joint, what I've described is the best we know how to do.
