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Wires out in the wing tips

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jpl(at)showpage.org
Guest

Posted: Fri Mar 31, 2006 6:28 am Post subject: Wires out in the wing tips

Well, I'm almost ready (after far too many years) to rivet wing  

skins.  I'm having a problem deciding about something.  I haven't  

done anything about making a path for any wires that I may need out  

in the wing tips.



I have a landing light near each wing tip (the duckworks system), so  

I know I'll need to run something for that. And of course, there will  

be position and strobe lights out in the tips.



For these lights, can I just install a grommet in each rib?  When I'm  

ready to wire everything, I'd then run the wires through the  

grommets, all bundled together?



I have no idea what size wires I'm going to need for these.  Heck, I  

don't even know if it's standard to run ground wires back to the  

battery or if I'm supposed to ground to the airframe.  One big  

aluminum wire 



Should I anticipate any sort of wing tip antennas?  I've heard from  

some guys who have had wing tip antennas that they don't work very  

well.  Someone who talked at the MN Wing meeting a few weeks ago  

about his fast airplane said he'd installed wing tip antennas and got  

lousy reception, so he switched to belly-mounted, tapered antennas.



Is this all something that can wait until much later in the process?   

I understand I only should rivet one set of skins (tops or bottoms)  

at this time, doing the other sets much further in the process.   

Would I be cursing myself if I waited on these wiring issues until then?



I know some guys have installed electrical conduit for their wires.   

This seems like unnecessary weight, but maybe it's a better idea than  

grommets.



As you can see, I really don't know what the best plan is for this.   

Comments from those who have gone before are appreciated -- even if  

you just want to say, "I did it this way, and I wouldn't do it that  

way again."



-Joe

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Hopperdhh(at)aol.com
Guest

Posted: Fri Mar 31, 2006 6:50 am Post subject: Wires out in the wing tips

Joe,

 

I just used snap bushings in each rib, no conduit.  When you run the  wires 

use cable ties about every 4 to 6 inches in the rib bays between the  ribs.  

Use mil spec aircraft type wire.  Van's wiring kit has  tables for the wire 

sizes for different amps and run lengths.  Also,  go to 

http://www.aeroelectric.com for lots of ideas.

 

The only thing I would do differently would be to make larger holes for  

larger snap bushings to begin with.  I had to make up drill extensions out  of 1/4 

rod to adapt to a Unibit to enlarge some holes after the wings were on  the 

plane.  Remember, you may want to put an autopilot servo in the  wing.  Mine is 

in the bellcrank bay, but some swear by the wingtip  location.  I wouldn't 

change my decision here!  One trouble spot is  where the wire transitions from 

wing to fuselage.  Before you put the wings  on it would make things easier if 

you plan a straight path here.

 

Hope this helps,

 

Dan Hopper

Walton, IN

RV-7A flying 146 hours

 

 

In a message dated 3/31/2006 9:31:51 A.M. Eastern Standard Time,  

jpl(at)showpage.org writes:

I  have a landing light near each wing tip (the duckworks system), so  

I  know I'll need to run something for that. And of course, there will   

be position and strobe lights out in the tips.



For these lights,  can I just install a grommet in each rib?  When I'm  

ready to  wire everything, I'd then run the wires through the  

grommets, all  bundled together?



I have no idea what size wires I'm going to need for  these.  Heck, I  

don't even know if it's standard to run ground  wires back to the  

battery or if I'm supposed to ground to the  airframe.  One big  

aluminum wire 



Should I anticipate  any sort of wing tip antennas?  I've heard from  

some guys who  have had wing tip antennas that they don't work very  

well.   Someone who talked at the MN Wing meeting a few weeks ago  

about his  fast airplane said he'd installed wing tip antennas and got  

lousy  reception, so he switched to belly-mounted, tapered antennas.



Is this  all something that can wait until much later in the process?   

I  understand I only should rivet one set of skins (tops or bottoms)  

at  this time, doing the other sets much further in the process.    

Would I be cursing myself if I waited on these wiring issues until  then?



I know some guys have installed electrical conduit for their  wires.   

This seems like unnecessary weight, but maybe it's a  better idea than  

grommets.



As you can see, I really don't  know what the best plan is for this.   

Comments from those who  have gone before are appreciated -- even if  

you just want to say, "I  did it this way, and I wouldn't do it that  

way  again."



-Joe

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Hopperdhh(at)aol.com
Guest

Posted: Fri Mar 31, 2006 7:26 am Post subject: Wires out in the wing tips

Joe,

 

I forgot to mention: it is not necessary to run a ground wire to the wings  

for the lights.  Just ground the lights to a screw through the wing rib,  etc.  

For the autopilot, I ran a separate ground (shield).  This is  how Cessnas 

and all the certificated airplanes that I know of do it.

 

Dan Hopper

RV-7A (flying)

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jpl(at)showpage.org
Guest

Posted: Fri Mar 31, 2006 7:55 am Post subject: Wires out in the wing tips

Dan,



Thanks for your comments.  They're very helpful.



-Joe



On Mar 31, 2006, at 9:24 AM, Hopperdhh(at)aol.com wrote:



 	  Quote: 	
		   



 Joe,



 I forgot to mention: it is not necessary to run a ground wire to  

 the wings

 for the lights.  Just ground the lights to a screw through the wing  

 rib,  etc.

 For the autopilot, I ran a separate ground (shield).  This is  how  

 Cessnas

 and all the certificated airplanes that I know of do it.



 Dan Hopper

 RV-7A (flying)

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HCRV6(at)comcast.net
Guest

Posted: Fri Mar 31, 2006 5:42 pm Post subject: Wires out in the wing tips

I used grommets in each wing rib and wished several times during finishing that I had used a plastic conduit or some of the flexible conduit that Van's sells. It would have been much easier to add wires that I forgot about in the initial installation.



If you do use grommets, be sure to run a continuous loop of strong cord through them for use in pulling wires through.  Keep it there until you are absolutely certain that you won't need any more wires.  



I used a single point ground at the firewall for everything else but I did ground the lights and strobe power packs to the airframe at the wing tips.  I have had no ground loop issues to deal with so I'd do it that way again.



I have a VOR antenna (Bob Archer's in the right wing tip and it works fine.  for com I'm convinced an external antenna is best for RV's but that's just me.  Mine is belly mounted.



--

Harry Crosby

RV-6 N16CX, 195 hours



 -------------- Original message ----------------------

From: Joseph Larson <jpl(at)showpage.org>

 	  Quote: 	
		   

 

 Well, I'm almost ready (after far too many years) to rivet wing  

 skins.  I'm having a problem deciding about something.  I haven't  

 done anything about making a path for any wires that I may need out  

 in the wing tips.

 

 I have a landing light near each wing tip (the duckworks system), so  

 I know I'll need to run something for that. And of course, there will  

 be position and strobe lights out in the tips.

 

 For these lights, can I just install a grommet in each rib?  When I'm  

 ready to wire everything, I'd then run the wires through the  

 grommets, all bundled together?

 

 I have no idea what size wires I'm going to need for these.  Heck, I  

 don't even know if it's standard to run ground wires back to the  

 battery or if I'm supposed to ground to the airframe.  One big  

 aluminum wire 

 

 Should I anticipate any sort of wing tip antennas?  I've heard from  

 some guys who have had wing tip antennas that they don't work very  

 well.  Someone who talked at the MN Wing meeting a few weeks ago  

 about his fast airplane said he'd installed wing tip antennas and got  

 lousy reception, so he switched to belly-mounted, tapered antennas.

 

 Is this all something that can wait until much later in the process?   

 I understand I only should rivet one set of skins (tops or bottoms)  

 at this time, doing the other sets much further in the process.   

 Would I be cursing myself if I waited on these wiring issues until then?

 

 I know some guys have installed electrical conduit for their wires.   

 This seems like unnecessary weight, but maybe it's a better idea than  

 grommets.

 

 As you can see, I really don't know what the best plan is for this.   

 Comments from those who have gone before are appreciated -- even if  

 you just want to say, "I did it this way, and I wouldn't do it that  

 way again."

 

 -Joe

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dsvs(at)comcast.net
Guest

Posted: Fri Mar 31, 2006 6:05 pm Post subject: Wires out in the wing tips

I used the flex conduit that Van's sells, works fine.  I made the holes a

little larger than speced to ease installation and then used RTV to glue the

conduit in so vibration would not cut it.  If you use conduit, make sure

that you put it in a place where it does not get in the way of bucking the

last skin.  This skin is hard enough to install without any additional

issues.  I also ran return wires for everything.  Don



--

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Mark Phillips in TN

Joined: 10 Jan 2006
Posts: 431
Location: Columbia, TN

Posted: Mon Apr 10, 2006 8:39 am Post subject: Wires out in the wing tips

In a message dated 3/31/06 8:31:51 AM Central Standard Time, jpl(at)showpage.org 

writes:



 	  Quote: 	
		   I haven't  

 done anything about making a path for any wires that I may need out  

 in the wing tips.


	


I used 5/8" CPVC water pipe through holes about 2" in front of the spar and 

about 1" from the top skin, held in place by a bead of E-6000 adhesive (GOOP) 

at the tip rib.  This has worked out extremely well as it took all of maybe 1 

minute to feed the wires out to the tips.  Easy to add/remove wires later as 

well.  Another advantage is that the conduit can be easily slid into the wing at 

final assembly instead of being in the way for riveting etc.  If you have 

already attached the ribs, you could make a simple jig keyed off of the large 

holes in the rib or possibly the tooling holes to drill the conduit holes in the 

same position.  I drilled mine before assembly as shown here:



http://websites.expercraft.com/n51pw/index.php?q=log_entry&log_id=4868



Click on the foto for a better view.



Mark Phillips -6A N51PW - 295 hours

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