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Rob's REBVAIR Project
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Date:  10-20-2015
Number of Hours:  3.00
Manual Reference:  
Brief Description:  Intercom jack wiring

Needed something to take my mind off things, and saw the final install wiring of the intercom as a nice, discrete, and achievable task for an evening.

I've detailed the fabrication of the 'box' elsewhere, so this was all about precision-cutting three pairs of shielded wires, stripping, dressing, and soldering them onto the jacks...without making one mistake. Making one wire too short to reach its intended position would mean starting over for all three, since I had assigned a specific location for each jack: from right to left in Image 2: pilot, co-pilot, passenger. I had more than enough excess wire in the harness for that scenario, but still would like to avoid re-work wherever possible.

It all went together rather well, and my only error was forgetting to add one piece of heat-shrink prior to soldering. Electrician's tape solved that one. Image 1 shows how tightly I was able to pack it all in there. It also shows the zip-tie that not only holds the nylon sleeve over the wire bundle (6 shielded wires and 4 (20 AWG) wires for the PTT switches), but also serves as a 'stop' to prevent the bundle from being pulled out of the box. In the finished install (Image 2) you can see a small segment of the caterpillar grommet added to prevent chafing at the semi-circular exit hole.

I tested it and it all worked correctly. It sounds crystal clear, and the PTT leads activate the transmit light on the unit when crossed. The Iso switch also correctly isolates the pilot's circuit. Music plays nicely through the music input 1/8 stereo receptacle. The PTT switches will be one of the last things installed since the controls will only go in at the end when I'm done under the panel.
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very compact arrangement

very compact arrangement

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final install just above torque tube

final install just above torque tube

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