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Rob's REBVAIR Project
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Date:  2-20-2015
Number of Hours:  6.00
Manual Reference:  
Brief Description:  Panel Part 9: PM3000 intercom harness

Finally done the PM3000 intercom wiring harness. This is not necessarily difficult but one has to proceed slowly and methodically. AircraftSpruce will sell you a complete harness for $245, but since the PM3000 unit comes with the D-sub connector, pins, and mic and headset jacks, you're really just paying for wire and time. Wire alone will run you about $60, so now it's all about how much your time is worth. Always up for a challenge, and armed with the aeroelectric connection tutorial on joining pig-tail grounds, I had this harness complete with very little fuss.

The secret to success here is to not expect to be able to have all (or even many) of the solder connections fit inside this D-sub backshell. Image one shows the 4 or so joints that WILL fit, and Image 2 shows the remaining 4 or so connections residing OUTSIDE the backshell (full disclosure, I only wired 3 of the 4 available circuits (pilot, copilot, and 1 passenger) since my Rebel will seat at most 3 people (2 adults and one child in the back)). If you only went with 2 places, it'd been even easier to close the backshell.

A complete test of the system will need to wait until all the inputs are connected, but a continuity check (pin number against appropriately labeled wire-end) suggests it is all good to go.
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before closing the backshell

before closing the backshell

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it all fits (sort of)

it all fits (sort of)

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