Archive for December, 2014

Tailcone wiring

Saturday, December 13th, 2014

No two ways about it, it's time to finish running the wires to the back of the airplane. I've been putting off this job forever, because it's not at all pleasant for me to be stuck heads-down inside a tapering metal tube made of delicate aluminum, trying not to crush the bulkhead flanges with my knees, while groping for dropped tools and burning my face on the shop light. In case you were wondering, that's a pretty apt description of what it's like to work inside the tailcone.

Anyway, I got all the various wires that have to exit the aft end of the airplane bundled neatly and run all the way to the back. Sorry, I didn't take any photos of the process (see previous paragraph).

Between the bulkheads, the wire bundle is secured to the bottom skin with tie wraps and these self-adhesive plastic anchors, from which I removed the self-adhesive stuff and attached with E6000 glue:

Back at the tail, I had already drilled to holes for passing the wiring through the aft bulkhead and vertical stabilizer spar ages ago. I'm not wild about this method for getting the wires through this area, but with the tailwheel mount being in the way there aren't too many other options.

On the outside, the wires can pass through the holes but there isn't room to use a proper grommet, so I used a couple layers of shrink tubing over the wires to prevent them from chafing on the holes.

For further wiring protection, I squirted RTV into the holes:

I merged the two wire strands back into a single bundle, and secured them with an adel clamp and a convenient bolt. That ought to keep the wire bundle from getting entangled with the rudder.

In the above photo you can see that there's a pair of small areas outboard of the vertical stabilizer spar in the lower corners. I might have been able to insert a grommet for a wiring bundle through this area, if I'd thought to do it before installing the tailwheel weldment. Yet another thing I'll do better on the next airplane project.

Some of the wires need to go upwards to the elevator and magnetometer, so they branch off and run up the side of the F-710 bulkhead and through a lightening hole in the aft deck. An adel clamp (invisible in this photo except for its mounting screw) keeps it in place.

Another view of the same area. The unused hole for the manual elevator trim cable makes a convenient place to put a grommet to pass the elevator trim wires through.

For now I've tied off the wires where they exit the fuselage, so they don't get tangled up with any of the other stuff piled up in my crowded garage: