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Preferred Bulkhead Disconnects

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longg(at)pjm.com
Guest

Posted: Tue Sep 30, 2008 9:07 am Post subject: Preferred Bulkhead Disconnects

I have two 5 wire bundles coming off the wings which control lights and

trim. My wings are detachable and I want to incorporate bulkhead

disconnects. What approach have any of you taken which is cost effective

and relatively easy to plug and unplug? I do not have easy access (one

3" hole) outside the cockpit so I need to be able to manage unplugging,

securing etc from inside. Pictures welcome.



I have thought about fast tabs something or 9 pin d-subs. I am thinking

two 9 pin d's would be bulky. They would also need a good size hole to

feed them back through when the wing is removed.

Thanks,

Glenn

mike109g6(at)insideconnec
Guest

Posted: Tue Sep 30, 2008 10:59 am Post subject: Preferred Bulkhead Disconnects

Glenn,

Aeroelectric advises the use of the 5 prong waterproof trailer towing 

male/female plugs which you could leave excess in wings.  Available 

anywhere, ie Lowe's, Home Depot, NAPA, AutoZone, etc.

Mike H 9A/8A

---

egilroy(at)gmail.com
Guest

Posted: Tue Sep 30, 2008 11:22 am Post subject: Preferred Bulkhead Disconnects

How about a WeatherPak connector? Available in your finer auto establishments...



On Tue, Sep 30, 2008 at 1:06 PM,  <longg(at)pjm.com (longg(at)pjm.com)> wrote:

 [quote]--> AeroElectric-List message posted by: <longg(at)pjm.com (longg(at)pjm.com)>

 

 

 I have two 5 wire bundles coming off the wings which control lights and

 trim. My wings are detachable and I want to incorporate bulkhead

 disconnects. What approach have any of you taken which is cost effective

 and relatively easy to plug and unplug? I do not have easy access (one

 3" hole) outside the cockpit so I need to be able to manage unplugging,

 securing etc from inside. Pictures welcome.

 

 I have thought about fast tabs something or 9 pin d-subs. I am thinking

 two 9 pin d's would be bulky. They would also need a good size hole to

 feed them back through when the wing is removed.

 

 

 Thanks,

 Glenn

 

 

 

 

 

 

 [b]

longg(at)pjm.com
Guest

Posted: Tue Sep 30, 2008 12:42 pm Post subject: Preferred Bulkhead Disconnects

Mike,

Great idea. Since my tiny trim wire is about 26 and those trailer

connectors are about 14, I'm not sure how that will tie together. I see

a lot of those with the pigtails already molded in. Are they available

without wires?



Glenn



--

mike109g6(at)insideconnec
Guest

Posted: Tue Sep 30, 2008 6:58 pm Post subject: Preferred Bulkhead Disconnects

Glenn,

I used it on my RAC electric trim servo in the elevator so that I could 

detach stab/elevator for transport.  RAC wires are 26awg.  Just expose an 

extra long piece of wire, make a 'J' shaped loop in the trailer wire, wrap 

the 26awg around the 14awg inside the J loop(5 or 6 wraps will do), crip 

down on the J loop lightly, just to snug the wires together.  Solder well 

with high grade silver solder.  When cooled cover soldered connection with a 

piece of heat shrink. Your done.  If you want to be extra careful, place a 

piece of large diameter heat shrink over the wire bundle before starting any 

of this and then heat shrink the entire 5 wire bundle under one piece, or 

wrap the entire assembly in high quality electrical tape or silicon tape.

Hope that this helps,

Mike H 9A/8A

---

dale.r(at)cox.net
Guest

Posted: Wed Oct 01, 2008 4:53 am Post subject: Preferred Bulkhead Disconnects

longg(at)pjm.com wrote:

 	  Quote: 	
		   



 Mike,

 Great idea. Since my tiny trim wire is about 26 and those trailer

 connectors are about 14, I'm not sure how that will tie together. I see

 a lot of those with the pigtails already molded in. Are they available

 without wires?

   


	


Glenn,



   It sounds as though you are thinking of the wrong connector.

Take a look at this:



http://www.delcity.net/delcity/servlet/catalog?parentid=8656&page=1



Your friendly local AutoZone, Kragen/Checker, NAPA, etc.,

will have an equivalent.  The wires are installed with set screws,

so really small wire may need to be doubled or tripled up.



Dale R.

longg(at)pjm.com
Guest

Posted: Wed Oct 01, 2008 6:50 am Post subject: Preferred Bulkhead Disconnects

Sounds like a plan, I'll give that a go. 



Thanks Mike



--

nuckolls.bob(at)cox.net
Guest

Posted: Wed Oct 01, 2008 7:16 pm Post subject: Preferred Bulkhead Disconnects

Picked up the end of this thread late and wasn't

sure what kinds of wires were being considered.



For 22 to 20 AWG wires at 4A or less, the d-subs

are connectors of choice. They're inexpensive and

tooling for installing the machined pins is also

inexpensive. For transitions between the gawd-awful

26AWG leadwires on a RAC trim actuator, consider

this technique:



http://aeroelectric.com/articles/macservo/macservo.html



If you need to break robust wires that carry

landing lights or pitot heat, consider this technique



http://aeroelectric.com/articles/wingwire/wingwire.html



or something similar.



Bob . . .

etienne.phillips(at)gmail
Guest

Posted: Wed Oct 01, 2008 11:31 pm Post subject: Preferred Bulkhead Disconnects

2008/10/2 Robert L. Nuckolls, III <nuckolls.bob(at)cox.net (nuckolls.bob(at)cox.net)>

 	  Quote: 	
		   --> AeroElectric-List message posted by: "Robert L. Nuckolls, III" <nuckolls.bob(at)cox.net (nuckolls.bob(at)cox.net)>

 

 For 22 to 20 AWG wires at 4A or less, the d-subs

 are connectors of choice. 	




Hi Bob



Would this be 4A per wire? I'd feel very nervous about putting that amount of current through an itty-bitty pin. Although here on the southern tip of the dark continent, we don't get the machined pins, only the useless pressed ones...

 

If think it's fine, then I'll believe you - I've just spent big bucks on this (see attached pic) military style breakout plug, which is rated at 5A per pin. 

Etienne

Breakout_Box_Small.jpg

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nuckolls.bob(at)cox.net
Guest

Posted: Thu Oct 02, 2008 7:27 am Post subject: Preferred Bulkhead Disconnects

At 09:27 AM 10/2/2008 +0200, you wrote:

 	  Quote: 	
		  2008/10/2 Robert L. Nuckolls, III 

<<mailto:nuckolls.bob(at)cox.net>nuckolls.bob(at)cox.net>

>

><<mailto:nuckolls.bob(at)cox.net>nuckolls.bob(at)cox.net>

>

>For 22 to 20 AWG wires at 4A or less, the d-subs

>are connectors of choice.



Hi Bob



Would this be 4A per wire? I'd feel very nervous about putting that amount 

of current through an itty-bitty pin.


	




    See:



http://aeroelectric.com/Mfgr_Data/Connectors/Positronic/HDC_Series.pdf



    Note contact current rating of 7.5A. In aircraft wire

    bundles this assumes a 20AWG wire. Of course, this

    drops to what ever the smaller wire is de-rated to

    for bundling . . . 5A in the case of 22AWG.



    Conservative designers will look at total connector

    current density and de-rate further if most or all

    of the pins are continuously loaded to max rated.



    The open barrel d-sub pins are generally rated the same electrically

    but they're much more process sensitive to the installation of

    single pins by the neophyte technician using tools like:



http://aeroelectric.com/Pictures/Tools/Crimp_Tools/bct-1.jpg



http://aeroelectric.com/Pictures/Tools/Crimp_Tools/obc-1.jpg

    The machined pins are essentially mil-spec and installed

    with either an inexpensive ratchet-handled 4-quadrant

    crimp tool like . . .



http://aeroelectric.com/Pictures/Tools/Crimp_Tools/rct-3.jpg



    or the super-cool, $high$ tool like . . .



http://aeroelectric.com/Pictures/Tools/Crimp_Tools/4-Quad/Daniels_4-Quad_1.jpg

http://aeroelectric.com/Pictures/Tools/Crimp_Tools/4-Quad/Daniels_4-Quad_2.jpg

http://aeroelectric.com/Pictures/Tools/Crimp_Tools/4-Quad/Daniels_4-Quad_3.jpg



    All of which produce a consistent installation of a

    machined pin.



Although here on the southern tip of the dark continent, we don't get the 

machined pins,

only the useless pressed ones...



    Steinair, and B&C both stock them.

 	  Quote: 	
		  If think it's fine, then I'll believe you - I've just spent big bucks on 

this (see attached pic) military style breakout plug, which is rated at 5A 

per pin. 


	


    Then the $time$ invested to swap horses right now

    is probably not a good investment. For others watching

    this thread, know that it is possible and practical to

    achieve nearly full-mil-spec connections in your small

    wires using the really good pins and anybody's removable-pin

    d-sub shells.



    Know too that if you need to run more than 5-7 amps

    though any one wire, you CAN parallel pins if you

    include a 12" or so total length of 22AWG wire for

    ballasting-resistance in series with each pin

    (10-20 milliohms). This mall resistance washes

    out pin-to-pin variables that make short-wire

   paralleling risky. See:



http://www.aeroelectric.com/Pictures/Connectors/D-Subminature/Paralleled_D-Sub_Pins.jpg



    I used this technique in a mil-qualified super-sonic

    target



http://aeroelectric.com/Pictures/Misc/GQM_1st_Ops_Flight.jpg



    power distribution controller . . .



http://aeroelectric.com/Pictures/Misc/GQM_Power_Dist.jpg



    to switch 20+ amp battery feeders. I de-rated to 3A

    per pin, had 12" 22AWG wire in series with each of

    7 paralleled pins to effect a high current feeder

    through the d-sub. It passed all the qualification tests.



    Bottom line is that the lowly D-Sub is an exceedingly

    good value if you can exploit the simple-ideas behind

    its design and amplications.



        Bob . . .



        ----------------------------------------)

        ( . . .  a long habit of not thinking   )

        ( a thing wrong, gives it a superficial )

        ( appearance of being right . . .       )

        (                                       )

        (                  -Thomas Paine 1776-  )

        ----------------------------------------

hooverra(at)verizon.net
Guest

Posted: Thu Oct 02, 2008 7:33 pm Post subject: Preferred Bulkhead Disconnects

The EN3 series from switchcraft is also a good choice available in both

bulkhead and cord mount, weather tite, not difficult to solder. They are

small, light, good strain relief, inexpensive and work well for the trim

system. I also have one in the panel for a Hand held radio power/audio

interface to the audio panel. (Available from Digikey

http://dkc3.digikey.com/PDF/T083/P0394.pdf)

http://www.switchcraft.com/products/pdf_files/connector-28c_schematic.pdf



Ralph & Laura Hoover

RV7A N527LR



--

nuckolls.bob(at)cox.net
Guest

Posted: Fri Oct 03, 2008 4:55 am Post subject: Preferred Bulkhead Disconnects

At 11:28 PM 10/2/2008 -0400, you wrote:

 	  Quote: 	
		  



The EN3 series from switchcraft is also a good choice available in both

bulkhead and cord mount, weather tite, not difficult to solder. They are

small, light, good strain relief, inexpensive and work well for the trim

system. I also have one in the panel for a Hand held radio power/audio

interface to the audio panel. (Available from Digikey

http://dkc3.digikey.com/PDF/T083/P0394.pdf)

http://www.switchcraft.com/products/pdf_files/connector-28c_schematic.pdf



Ralph & Laura Hoover

RV7A N527LR


	


   Ralph, Thanks for the heads-up on this one! Price and specs

   are right. I've added it to the Manufacture's data files at:



http://aeroelectric.com/Mfgr_Data/Connectors/Switchcraft/EN3_Digikey.pdf



   Bob . . .



        ----------------------------------------)

        ( . . .  a long habit of not thinking   )

        ( a thing wrong, gives it a superficial )

        ( appearance of being right . . .       )

        (                                       )

        (                  -Thomas Paine 1776-  )

        ----------------------------------------

jim-bean(at)att.net
Guest

Posted: Fri Oct 03, 2008 8:51 am Post subject: Preferred Bulkhead Disconnects

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