So because of limited space in the panel in my Electrical Bay I had to have a pass through that was small enough to go through the firewall. I ended up not being able to find one. ACS has one but it appears the manufacturer has gone out of business. So my plan was to go to Mcmaster-Carr and get material and make my own. I bought some stainless flat stock and round tubing.
Having never welded stainless steel and the steel being very thin I went and ordered some items for my Miller welder. Some 1/16" tungsten and smaller cups for the gas. I cut the pieces for a progotype part to practice welding. I welded them together and the weld looked acceptable UNTIL I looked at the back side...too much heat and power....it burned through.
I cut a couple more pieces and made them the dimensions that I intended for the "real" pass thru. I decided I may as well try to make a good one. Well after making some changes on my welder and getting a little better setup I welded it up. Bingo...the weld wasn't like a professional who does it on a daily basis but it was very good and no burn through!
So one half of the pass through is done! I took a break from the shop and did a little planning on where I am going to put the LEMOs in the airplane for the front and back headsets.
