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starter wire breaking

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kitfox555(at)sbcglobal.ne
Guest

Posted: Sun Aug 30, 2009 3:35 pm Post subject: starter wire breaking

This is the second time my starter positive wire has broke at the connection on the starter bolt, has anyone had this happen to them? I'm thinking of adding a zip tie around the wire and the starter to stop the vibration that makes the wire connector to break off just before the nut that tightens it on the starter,  582 Grey head, any input would be great  thanks,  Jerry 



 Jerry Evans 

 KitfoxII

 Magalia Calif.

 N582'er'

 kitfox 555

 [quote][b]

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Tom Jones

Joined: 12 Mar 2006
Posts: 752
Location: Ellensburg, WA

Posted: Sun Aug 30, 2009 5:19 pm Post subject: Re: starter wire breaking

Jerry, is the wire the stuff that came with the original Kit?  The starter wire that came with my kit was way too stiff.  It was about 10 or 12 strands of thick copper.  Mine broke at the same spot as yours about a week after the first flight.  I replaced it with some marine wire from the boat shop.  It is lots and lots of fine copper strands and very flexible.  Looks about like welding lead but has a red jacket.  75 hours now and no more problems.

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_________________
Tom Jones
Classic IV
503 Rotax, 72 inch Two blade Warp
Ellensburg, WA

Paul A. Franz, P.E.

Joined: 02 Dec 2008
Posts: 280
Location: Bellevue WA

Posted: Sun Aug 30, 2009 5:43 pm Post subject: starter wire breaking

On Sun, August 30, 2009 4:31 pm, jerry evans wrote:

 	  Quote: 	
		   This is the second time my starter positive wire has broke at the connection on the

 starter bolt, has anyone had this happen to them? I'm thinking of adding a zip tie

 around the wire and the starter to stop the vibration that makes the wire connector to

 break off just before the nut that tightens it on the starter.


	


That will probably do it. If you can restrain the vibrating cable at half the

unrestrained length that will roughly double the natural frequency of vibration as

well as restrict the amplitude. Both effects will likely extend the connector life

considerably if not totally eliminate the problem. On the downside, it might just

break in a different place next time. The restraint needs to be tight and the clamping

stress spread out enough to prevent crushing and insulation damage.

-- 

Paul Franz

425.440.9505 (O)

425.241.1618 (C)



"Freedom had been hunted round the globe; reason was considered as

rebellion; and the slavery of fear had made men afraid to think. But

such is the irresistible nature of truth, that all it asks, and all it

wants, is the liberty of appearing."

-- Thomas Paine, Rights of Man, 1791



"The essence of Government is power; and power, lodged as it must be

in human hands, will ever be liable to abuse."

-- James Madison



"[J]udges, therefore, should be always men of learning and experience

in the laws, of exemplary morals, great patience, calmness, coolness,

and attention. Their minds should not be distracted with jarring

interests; they should not be dependent upon any man, or body of

men."

-- John Adams



"When a business or an individual spends more than it makes, it goes

bankrupt. When government does it, it sends you the bill. And when

government does it for 40 years, the bill comes in two ways: higher

taxes and inflation. Make no mistake about it, inflation is a tax and

not by accident."

-- Ronald Reagan



If you don't read the newspaper you are uninformed, if you do read

the newspaper you are misinformed.

-- Mark Twain



"Liberty has never come from the government. Liberty has always come

from the subjects of government. The history of liberty is the

history of resistance. The history of liberty is a history of the

limitation of governmental power, not the increase of it."

-- President Woodrow Wilson (1856-1924)

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_________________
Paul A. Franz, P.E.
Registration/Aircraft - N14UW/Merlin GT
Engine/Prop - Rotax 914/NSI CAP
Bellevue WA
425.241.1618 Cell
425.440.9505 Office

icubob(at)gmail.com
Guest

Posted: Mon Aug 31, 2009 4:57 am Post subject: starter wire breaking

jerry,

  fine stranded wire from a welding supply is a must if you dont already have it. also, some place along the wire you can attach it to the starter will help. last, a lot of solder following the strands out of the attach fitting i think makes the wire more likely to fail from movement.

   bob noffs

 On Sun, Aug 30, 2009 at 8:33 PM, Paul Franz <paul(at)eucleides.com (paul(at)eucleides.com)> wrote:

 [quote]--> Kitfox-List message posted by: "Paul Franz" <paul(at)eucleides.com (paul(at)eucleides.com)>

  



On Sun, August 30, 2009 4:31 pm, jerry evans wrote:

 	  Quote: 	
		   This is the second time my starter positive wire has broke at the connection on the

 starter bolt, has anyone had this happen to them? I'm thinking of adding a zip tie

 > around the wire and the starter to stop the vibration that makes the wire connector to
	




 	  Quote: 	
		   break off just before the nut that tightens it on the starter.


	


That will probably do it. If you can restrain the vibrating cable at half the

 unrestrained length that will roughly double the natural frequency of vibration as

well as restrict the amplitude. Both effects will likely extend the connector life

considerably if not totally eliminate the problem. On the downside, it might just

 break in a different place next time. The restraint needs to be tight and the clamping

stress spread out enough to prevent crushing and insulation damage.

--

Paul Franz

425.440.9505 (O)

425.241.1618 (C)

 

"Freedom had been hunted round the globe; reason was considered as

rebellion; and the slavery of fear had made men afraid to think. But

such is the irresistible nature of truth, that all it asks, and all it

 wants, is the liberty of appearing."

-- Thomas Paine, Rights of Man, 1791



"The essence of Government is power; and power, lodged as it must be

in human hands, will ever be liable to abuse."

 -- James Madison



"[J]udges, therefore, should be always men of learning and experience

in the laws, of exemplary morals, great patience, calmness, coolness,

and attention. Their minds should not be distracted with jarring

 interests; they should not be dependent upon any man, or body of

men."

-- John Adams



"When a business or an individual spends more than it makes, it goes

bankrupt. When government does it, it sends you the bill. And when

 government does it for 40 years, the bill comes in two ways: higher

taxes and inflation. Make no mistake about it, inflation is a tax and

not by accident."

-- Ronald Reagan



If you don't read the newspaper you are uninformed, if you do read

 the newspaper you are misinformed.

-- Mark Twain



"Liberty has never come from the government. Liberty has always come

from the subjects of government. The history of liberty is the

history of resistance. The history of liberty is a history of the

 limitation of governmental power, not the increase of it."

-- President Woodrow Wilson (1856-1924)

  

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