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Tigers2007 wrote: I remember cleaning up the wire ends on my Cessna by crimping, soldering, and sealing with double-wall heat shrink. It is what I was taught in high school and what I always do with all automotive wiring. I couldn't believe the flimsy crimps that on this bird.

And, as you may know, the use of solder itself in aircraft wiring connections is not without controversy. AC43-13 is the bible on this stuff. Most believe that either method, done properly, works well. The mechanical support you mentioned (heavy insulation) is important.

I could be mistaken, but it was my understanding that the Jabiru 3300 in question used a system for EFI that required electrical power, and this failure could be the reason it did not continue to operate.

I am probably wrong, so take this as one person's understanding of one incident.


Robbie Culver
Sonex 1517
Chicagoland
Tails and Wings complete - finishing fuselage.
N1517S reserved

Good point. I've done a fair share of head-scratching in certain cases of OEM wiring. But they have certainly tried to work out kinks. Look at the Delphi Metri-Pak system. Yeah, priced very high but you get a high quality "fail-safe" weatherproof connection that includes wire stress relief. I suppose that could make the simple now complicated? Maybe its time for the AC's to investigate upgrades in their best practice recommendations.

Those of us who deviate from the KISS mentality, run the risk of introducing unintended failure modes. When those failure modes are single points, those points must be carefully executed. Just read a quiz in the AOPA mag that asked what the Jesus Nut was. Never heard of it. Its the single nut that holds on rotor head to the shaft on a helicopter. So if you have a Jesus Nut or many, you better pay attention to them.

I used to design helicopter FBW systems. We had a rule (among others) that no two critical failures would prevent continued safe flight. Things do fail. I am not wild about solder. You won't see much, if any, on a Sikorsky machine.
You also will not see a Jesus nut on a Sikorsky helicopter. Many bolts instead.

I have a few Jesus Nuts. Like the pushrod connections and the tail mixer. But I think most of my electrical stuff won't bring me down, save a fire. Dual independent ignition based on mags. Even if my battery is disconnected, I can still keep flying.