X-Virus-Scanned: clean according to Sophos on Logan.com X-SpamCatcher-Score: 1 [X] Return-Path: Sender: To: lml Date: Sat, 13 Jan 2007 11:50:37 -0500 Message-ID: X-Original-Return-Path: Received: from [69.146.254.20] (HELO arilabs.net) by logan.com (CommuniGate Pro SMTP 5.1.4) with ESMTP id 1756565 for lml@lancaironline.net; Sat, 13 Jan 2007 11:43:24 -0500 Received-SPF: none receiver=logan.com; client-ip=69.146.254.20; envelope-from=Kevin@arilabs.net MIME-Version: 1.0 Content-Type: multipart/alternative; boundary="----_=_NextPart_001_01C73731.D4CB58A5" Subject: RE: [LML] Re: Connectors Content-class: urn:content-classes:message X-MimeOLE: Produced By Microsoft Exchange V6.5 X-Original-Date: Sat, 13 Jan 2007 09:40:24 -0700 X-Original-Message-ID: <7141427652BB3049A7DBF1084B67805B0F7B4D@penumbra.arilabs.net> X-MS-Has-Attach: X-MS-TNEF-Correlator: Thread-Topic: [LML] Re: Connectors Thread-Index: Acc3LU1JRZxWFDa2Te+sqOpVGMvedwAAuCqQ From: "Kevin Stallard" X-Original-To: "Lancair Mailing List" This is a multi-part message in MIME format. ------_=_NextPart_001_01C73731.D4CB58A5 Content-Type: text/plain; charset="us-ascii" Content-Transfer-Encoding: quoted-printable Solder joints are bad. =20 The only solder joints you should use are the solder filled heat shrink tube sections used to splice wires together. Otherwise, don't use them. =20 A soldered wire to a hard connection point can lead to the wire breaking off because of vibration. Solder will stiffen the wire such that it becomes prone to breaking due to fatigue. It is much like taking a stiff copper wire and bending back and forth until it breaks. This doesn't happen with stranded copper wire, until you stiffen the strands with solder. =20 What you want is a good crimp. Don't use solder. Don't use a crimping tool from Radio Shack either. In fact, if your crimping tool costs less than $100.00, throw it away. =20 You may spend a lot of money on a proper, CALIBRATED crimping tool, but these are the only things you should use. =20 It will take a bit of research, but there are all sorts of crimping tools and aerospace worthy connectors that will do a fantastic job for you. You will need a little practice. It will be well worth the time and money you spend on it. Don't be cheap... =20 Kevin L2K-291 =20 =20 =20 =20 =20 ________________________________ From: Lancair Mailing List [mailto:lml@lancaironline.net] On Behalf Of Robert R Pastusek Sent: Saturday, January 13, 2007 9:10 AM To: lml Subject: [LML] Re: Connectors =20 Ian, =20 My complete panel (IV-P with Chelton EFIS) is removable, but you'll be surprised at the number of connectors needed--power, signal (LOTS of these), pitot, static and lots of antennae. I built it that way so I could upgrade/modify it "more easily" over time. It will take a couple of years or so to tell if it was worth the effort and extra cost. On connectors--I used AMP phenolic body connectors with gold-plated pins for power and signal--mostly from Mouser.=20 =20 I'll pass on some advice Brent Regan gave me many years ago: The best/most reliable connector is a good solder joint--or no connector at all. When you must use one, make it the best you can afford." Starting with this simple and sound advice, I've managed to scatter connectors all over my airplane, but also have left working loops and solder connections where possible--trim motor connections to the aircraft wiring, for example. =20 I think this is a judgment call in any case. I'd be interested in hearing from folks that have gone the "removable panel" route and have then actually done so. =20 Bob Pastusek =20 =20 -----Original Message----- From: Lancair Mailing List [mailto:lml@lancaironline.net]On Behalf Of Ian Crowe Sent: Friday, January 12, 2007 5:04 PM To: lml Subject: [LML] Connectors I am going to redo my right hand side instrument panel to accomodate some new equipment. =20 I would like to build the panel on the bench and hook it up in the a/c using connectors. The right hand side of my panel houses all the switches, circuit breakers and engine gauges. This will make the panel easily removeable if needs be. =20 Does anyone have any comments on the idea of using connectors? Does it pose any questions of reliability or potential failure? =20 If anyone has done it, what connectors did they use and where did they get them? =20 Ian B. Crowe LNC 2 C-FKRO ------_=_NextPart_001_01C73731.D4CB58A5 Content-Type: text/html; charset="us-ascii" Content-Transfer-Encoding: quoted-printable

Solder joints are = bad.

 

The only solder joints you should = use are the solder filled heat shrink tube sections used to splice wires = together.  Otherwise, don’t use them.

 

A soldered wire to a hard = connection point can lead to the wire breaking off because of vibration.  Solder = will stiffen the wire such that it becomes prone to breaking due to = fatigue.  It is much like taking a stiff copper wire and bending back and forth until = it breaks.  This doesn’t happen with stranded copper wire, until = you stiffen the strands with solder.

 

What you want is a good = crimp.  Don’t use solder.  Don’t use a crimping tool from Radio Shack = either.  In fact, if your crimping tool costs less than $100.00, throw it = away.

 

You may spend a lot of money on a = proper, CALIBRATED crimping tool, but these are the only things you should = use.

 

It will take a bit of research, but = there are all sorts of crimping tools and aerospace worthy connectors that = will do a fantastic job for you.  You will need a little practice.  It = will be well worth the time and money you spend on it.  Don’t be = cheap…

 

Kevin

L2K-291

=

 

 

 

 

 

From: = Lancair Mailing List = [mailto:lml@lancaironline.net] On Behalf Of Robert R Pastusek
Sent: Saturday, January = 13, 2007 9:10 AM
To: lml
Subject: [LML] Re: = Connectors

 

Ian,

 

My complete panel (IV-P with = Chelton EFIS) is removable, but you'll be surprised at the number of connectors = needed--power, signal (LOTS of these), pitot, static and lots of antennae. I built it = that way so I could upgrade/modify it "more easily" over time. It will = take a couple of years or so to tell if it was worth the effort and extra = cost. On connectors--I used AMP phenolic body connectors with gold-plated pins = for power and signal--mostly from Mouser.

 

I'll pass on some advice Brent = Regan gave me many years ago: The best/most reliable connector is a good = solder joint--or no connector at all. When you must use one, make it the best = you can afford." Starting with this simple and sound advice, I've managed = to scatter connectors all over my airplane, but also have left working = loops and solder connections where possible--trim motor connections to the = aircraft wiring, for example.

 

I think this is a judgment call in = any case. I'd be interested in hearing from folks that have gone the "removable panel" route and have then actually done = so.

 

Bob = Pastusek

 

 

-----Original = Message-----
From: Lancair Mailing List [mailto:lml@lancaironline.net]On Behalf Of Ian Crowe
Sent: Friday, January 12, = 2007 5:04 PM
To: lml
Subject: [LML] = Connectors

I am going to redo my right hand side instrument = panel to accomodate some new equipment.

 

I would like to build the panel on the bench and hook = it up in the a/c using connectors.  The right hand side of my panel = houses all the switches, circuit breakers and engine gauges. This will make the = panel easily removeable if needs be.

 

Does anyone have any comments on the idea of using = connectors?  Does it pose any questions of reliability or potential = failure?

 

If anyone has done it, what connectors did they use = and where did they get them?

 

Ian B. Crowe
LNC 2  C-FKRO

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