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Wiring around wing carry through on 601

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blb7037(at)cox.net
Guest

Posted: Wed May 24, 2006 3:00 pm Post subject: Wiring around wing carry through on 601

Has anyone got any good ideas on how to get wiring and the pitot tubes =

from the rear fuselage to the front cabin area . Getting around the wing =

carry through has given me fits. Zenith says they don't want me to drill =

holes in it for grommets even though AMD did. AMD says they are working =

on a way to go along the top rail. I don't see a good way to do that . I =

have the center stick and it and the rudder cable take up the only =

lightning hole.



I am thinking about running them along the inside edge of both seats in =

plastic conduits and hoping the upholstery will be thick enough to =

conceal and protect the conduits and not be objectionable. There are a =

lot of wires and tubes to go through there on my installation.



Brian Briggerman

Fountain Hills, AZ=20

90% done and 190% to go

larry(at)macsmachine.com
Guest

Posted: Wed May 24, 2006 4:17 pm Post subject: Wiring around wing carry through on 601

Brian,

You're right, there's few options in that area, but you might consider 

putting the bundled wires thru the hole just above the pivot plate

using the same lightening hole.  A split rubber hose on the edge and a 

plastic bundle wrap will protect it all.  See the links below

that show the problems you describe and it does include brake lines, 

fuel lines, pitot lines, all wiring from tail, wings, and battery 

cables. It can be done by adding supporting carry-throughs where needed, 

but you need to start early in the planning.



http://www.macsmachine.com/images/largeassembly2/full/brakelines.gif

http://www.macsmachine.com/images/largeassembly2/full/consolecleco.gif

http://www.macsmachine.com/images/largeassembly2/full/consolecutaway.gif

http://www.macsmachine.com/images/largeassembly2/full/batterycableroute.gif

http://www.macsmachine.com/images/largeassembly2/full/bundlbus.gif

http://www.macsmachine.com/images/largeassembly2/full/bundlsupts.gif

http://www.macsmachine.com/images/largeassembly2/full/pitobracket.gif



Hope some of this is helpful,



Larry McFarland  601HDS at www.macsmachine.com

do not archive



Brian Briggerman wrote:



 	  Quote: 	
		  



Has anyone got any good ideas on how to get wiring and the pitot tubes =

from the rear fuselage to the front cabin area . Getting around the wing =

carry through has given me fits. Zenith says they don't want me to drill =

holes in it for grommets even though AMD did. AMD says they are working =

on a way to go along the top rail. I don't see a good way to do that . I =

have the center stick and it and the rudder cable take up the only =

lightning hole.



I am thinking about running them along the inside edge of both seats in =

plastic conduits and hoping the upholstery will be thick enough to =

conceal and protect the conduits and not be objectionable. There are a =

lot of wires and tubes to go through there on my installation.



Brian Briggerman

Fountain Hills, AZ=20

90% done and 190% to go

JAPhillipsGA(at)aol.com
Guest

Posted: Wed May 24, 2006 4:47 pm Post subject: Wiring around wing carry through on 601

Brian, I drilled two holes near the left seatbelt connector and ran the tubes 

under the seat area to the center spar. Then I drilled two holes in the spar 

and grommeted both sides and they exited about mid calf. Connected to two "L"s 

and routed both up into the instrument panel. I know ZAC does not want us to 

drill holes in the spar, but they have not designed an alternate method. Also, 

I installed the duel sticks and you have to drill four holes (?) for that to 

attach to the spar so what is two more. Lastly, if you have ever looked at the 

center spar for a Piper Warrior you will see holes you can run your hand 

through and really if our XL's are so fragile (I personally know mine is not) that 

the wings fall off because of two little holes in the spar, we shouldn't be 

flying them. FWIW, best regards, Bill of Georgia N505WP 601XL-3300 70 hours

craig(at)craigandjean.com
Guest

Posted: Wed May 24, 2006 6:49 pm Post subject: Wiring around wing carry through on 601

I've got to ask: why are there what look like two cigarette lighter outlets

opening out the bottom of your fuselage?



-- Craig



--

VideoFlyer(at)aol.com
Guest

Posted: Wed May 24, 2006 6:49 pm Post subject: Wiring around wing carry through on 601

The 601XL has only one hole in the spar inside the cabin.  And it already has 

rudder cables and the the torque tube running through it.  I looked long and 

hard at different ways to route pitot tubes and wires and brake lines over 

that spar.  A buddy of mine said to me, "Why don't you run them underneath the 

spar?  It looks like there's a channel under there."  And indeed, there is an 

exterior reinforcing channel running the length of the cockpit....right 

underneath the spar.  It's a simple matter of enclosing that channel, and putting 

holes through the cabin floor in front of and and behind the spar.  I am running 

my brake lines, my battery cables and pitot tubes from behind the seat, through 

a hole in the floor of the fuselage, through the newly enclosed channel (of 

course, you wait to enclose the channel until all the lines are routed 

properly) and back into the cabin through a hole in the floor up by the rudder pedals. 

 It's clean...keeps a lot of clutter off the side walls, and it's very easy 

to do.  I'll try to post some pictures.  



Dave Harms

601XL/Corvair

tonyplane(at)bellsouth.ne
Guest

Posted: Wed May 24, 2006 8:16 pm Post subject: Wiring around wing carry through on 601

I also agonized over this, but found that the brake lines and the pitot =

and static tubes do in fact fit.  I also had previously askedZenith if I =

could drill some access holes at the center of the center spar webs as =

this is where the lowest loads occur (neutral axis) but the reply was =

"not recommended".I enclosed the brake and pitot/static lines in ribed =

wire conduit and used adel type clamps on both sides of the spar to hold =

them close to the bottom edge of the center spar webs' lightening holes =

and to prevent movement.  I have dual sticks and there is absolutely no =

contact with any moving parts.For electrical wiring, I used both sides =

of the cockpit rail channel.  I have wiring for the flaps, autopilot, =

ELT (phone line), cabin lights, tail light, EFIS magnetometer and coax =

for comm and transponder tucked underneath the cockpit rails. and =

exiting with ribbed conduit at the end near the seats and then going =

aft, down to the area behind the seats or in the case for the cabin =

lights and magnetometer up around the cargo compartment bow.  Somehow it =

all fit.  I was very careful that there was absolutely no chafing, or =

proved chafing protection where possibly required.Tony =

GrazianoN493TG601XL/Jab3300A; 99.8 hrsWiring around wing carry through =

on 601Zenith-List message posted by: "Brian Briggerman" =

<blb7037(at)cox.net>



Has anyone got any good ideas on how to get wiring and the pitot tubes =

=3D

from the rear fuselage to the front cabin area . Getting around the wing =

=3D

carry through has given me fits. Zenith says they don't want me to drill =

=3D

holes in it for grommets even though AMD did. AMD says they are working =

=3D

on a way to go along the top rail. I don't see a good way to do that . I =

=3D

have the center stick and it and the rudder cable take up the only =3D

lightning hole.



I am thinking about running them along the inside edge of both seats in =

=3D

plastic conduits and hoping the upholstery will be thick enough to =3D

conceal and protect the conduits and not be objectionable. There are a =

=3D

lot of wires and tubes to go through there on my installation.



Brian Briggerman

Fountain Hills, AZ=3D20

90% done and 190% to go

larry(at)macsmachine.com
Guest

Posted: Thu May 25, 2006 5:21 am Post subject: Wiring around wing carry through on 601

Craig,

I wanted a simple way to charge both batteries separately using Battery 

Tenders that can be left on during the winter.

http://www.macsmachine.com/images/electrical/full/chargeportassy2.gif

http://www.macsmachine.com/images/electrical/full/chargeplugs.gif

I also have a Dzus cover for when it's not being used.



Larry McFarland - 601HDS



Craig Payne wrote:



 	  Quote: 	
		  



I've got to ask: why are there what look like two cigarette lighter outlets

opening out the bottom of your fuselage?



-- Craig

cmaggart(at)sprintmail.co
Guest

Posted: Thu May 25, 2006 6:14 am Post subject: Wiring around wing carry through on 601

Brian, I have the same problem.  Nick at ZAC didn't like the idea of =

drilling holes in the spar web.  I am running as much as possible =

beneath the canopy sills.  I am running the hydraulic lines and flap =

wiring through the holes in the forward, outboard seat bottoms ( in =

separate conduits).  I was able to get the elevator trim and tail light =

wires under the l/h canopy sill.  I ran the comm and GPS antenna cables =

under the r/h canopy sill.  I used spiral wrap or clear plastic tubing =

to protect the cables and hoses.  I  have not run the pitot/static lines =

yet, but plan to bring them through the same hole (in the seat bottom) =

as the brake line uses.  Hopefully the upholstery will cover most of =

this up.



I seriously considered making a tunnel under the floor to run the large =

amount of wires and tubes,  It would have been nice if ZAC provided some =

means of penetrating the spar.   I wonder how they ran the wiring on the =

demonstrator?



Chuck Maggart

XL, structure done, installations nearly done

nfivesl(at)yahoo.com
Guest

Posted: Thu May 25, 2006 7:11 am Post subject: Wiring around wing carry through on 601

Brian: 



I used split loom and ran it through the center hole

in the spar near the bottom.  It runs under the

control parts for the center yoke and rudder cables. 

I was able to use the round, split-loom clamps to hold

it out of the way of the controls.  I plan to tie-wrap

the tubing to this also to hold it out of the way of

the controls.  I have a lot of wires in my yoke for

PTT, trim tabs, and frequency switch that are

contained in split loom also and tie-wrapped to the

yoke.



I'll try to take a photo of the loom, etc. this

afternoon and post it.  



Scott Laughlin

601XL/Corvair

Finished BRS Harness installation,

working on Canopy

http://www.cooknwithgas.com/index.html



 	  Quote: 	
		   

 Briggerman" <blb7037(at)cox.net>

 

 Has anyone got any good ideas on how to get wiring

 and the pitot tubes =

 from the rear fuselage to the front cabin area .


	


__________________________________________________

blb7037(at)cox.net
Guest

Posted: Thu May 25, 2006 8:29 am Post subject: Wiring around wing carry through on 601

Tony:



That looks like the best way to honor Zenith's request not to drill the =

carry through. I wondered if I could get by with running a ribbed =

conduit along the inboard edge of the seat cushions and let the seat =

cushion hide the conduits? I did see an AMD built 601 here in Arizona =

yesterday and they drill two holes three inches from the outboard end of =

the carry through midway between top and bottom for their stuff and it =

got certified "Light Sport" with that.=20



I appreciate everyone's response to the problem.



Brian Briggerman

601XL builder=20

Fountain Hills, AZ

blb7037(at)cox.net
Guest

Posted: Fri May 26, 2006 5:58 am Post subject: Wiring around wing carry through on 601

Chuck:



Thanks for your response. I am heading the same way you are. I did run =

my brake lines in Aluminum tubing and run them along the bottom longeron =

to get them forward of the wing carry through. That helped a lot but =

it's amazing how many wires show up in a Light Sport Airplane. I am =

using the external wire way as a backup plan that several listeners have =

suggested. I do have access to an AMD built 601 and they had a lot of =

the same problems we are having. They drilled two holes for a 1/2" ID =

grommet in the carry through three inches from the outboard end and =

three inches up from the bottom. They are running right along side the =

fuel lines which is against 43-13 guidelines. Anyway they got it =

certified that way.



Cheers!



Brian Briggerman

Fountain Hills, AZ

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