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Wire Installation Guidelines

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jluckey(at)pacbell.net
Guest

Posted: Wed Oct 11, 2023 9:56 am Post subject: Wire Installation Guidelines

What are the "rules" for running wires along longerons in aluminum airframes?





I see things like:

1. simply ty-rapping the wire to the longeron every 12 to 18 inches.  I see this mostly in Experimentals.



2. using an Adell clamp, at that same interval, for wire bundles and sometimes even for single conductor.  Typically in certified aircraft and airliners/biz jets/military helos, etc.



Back when I was a kid, I was helping a friend wire a racing motorcycle and ty-rapped a wire directly to the frame of the bike and promptly got chewed-out.  Apparently using that installation technique is verboten because it causes the wire to chafe against the frame with the high-frequency vibrations coming from racing engines.



Which way is "the right way"?





-Jeff

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harrismarkr(at)hotmail.co
Guest

Posted: Wed Oct 11, 2023 12:02 pm Post subject: Wire Installation Guidelines

2

 

  

 

 Sent from Outlook for iOS

 

  From: owner-aeroelectric-list-server(at)matronics.com <owner-aeroelectric-list-server(at)matronics.com> on behalf of Jeff Luckey <jluckey(at)pacbell.net>

 Sent: Wednesday, October 11, 2023 6:55:34 PM

 To: Aeroelectric List <aeroelectric-list(at)matronics.com>

 Subject: Wire Installation Guidelines  

 

   What are the "rules" for running wires along longerons in aluminum airframes?

 

 

 

 

 I see things like:

 

 

 1. simply ty-rapping the wire to the longeron every 12 to 18 inches.  I see this mostly in Experimentals.

 

 2. using an Adell clamp, at that same interval, for wire bundles and sometimes even for single conductor.  Typically in certified aircraft and airliners/biz jets/military helos, etc.

 

 

 

 Back when I was a kid, I was helping a friend wire a racing motorcycle and ty-rapped a wire directly to the frame of the bike and promptly got chewed-out.  Apparently using that installation technique is verboten because it  causes the wire to chafe against the frame with the high-frequency vibrations coming from racing engines.

 

 

 

 Which way is "the right way"?

 

 

 

 

 -Jeff

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Ceengland

Joined: 11 Oct 2020
Posts: 381
Location: MS

Posted: Wed Oct 11, 2023 1:42 pm Post subject: Wire Installation Guidelines

Or at least not 1 (at least as stated),       for the reason given in 2. 

       Adel clamps are the traditional way, but there are other       techniques to space the wire away from the structure. 

       

       On 10/11/2023 3:01 PM, mark harris wrote:

     

      	  Quote: 	
		                                    2

         

                    

           

           Sent from Outlook for iOS

       

              From:           owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com)           <owner-aeroelectric-list-server(at)matronics.com> (owner-aeroelectric-list-server(at)matronics.com) on behalf           of Jeff Luckey <jluckey(at)pacbell.net> (jluckey(at)pacbell.net)

           Sent: Wednesday, October 11, 2023 6:55:34 PM

           To: Aeroelectric List           <aeroelectric-list(at)matronics.com> (aeroelectric-list(at)matronics.com)

           Subject: Wire Installation           Guidelines          

       

                           What are the "rules" for             running wires along longerons in aluminum airframes?

           

           

           

           

           I see things like:

           

           

           1. simply ty-rapping the             wire to the longeron every 12 to 18 inches.  I see this             mostly in Experimentals.

           

           2. using an Adell clamp, at             that same interval, for wire bundles and sometimes even for             single conductor.  Typically in certified aircraft and             airliners/biz jets/military helos, etc.

           

           

           

           Back when I was a kid, I             was helping a friend wire a racing motorcycle and ty-rapped             a wire directly to the frame of the bike and promptly got             chewed-out.  Apparently using that installation technique is             verboten because it causes the wire to chafe against the             frame with the high-frequency vibrations coming from racing             engines.

           

           

           

           Which way is "the right             way"?

           

           

           

           

           -Jeff

           

           

           

           

           

         

       

     	
     

   Virus-free.www.avast.com[url=#DAB4FAD8-2DD7-40BB-A1B8-4E2AA1F9FDF2] [/url]

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_________________
Charlie

ashleysc(at)broadstripe.n
Guest

Posted: Wed Oct 11, 2023 4:27 pm Post subject: Wire Installation Guidelines

Hi Mark and Charlie;

Adel clamps are ideal, but it takes two, one to surround a bundle of wires and one to mount them to a piece of structure (tubing for instance. Things can get quite Adel Clamp heavy and congested.

My compromise was to use two turns of Rescue Tape (silicone tape) around the bundle of wires and two turns around the structural element. Then tie wire the two bundles together so that rescue tape contacts rescue tape. Since the rescue tape cures to itself, there will be no relative motion due to vibration, and each is protected (wire and structure). In the fuselage and wings I used black nylon wire ties. In the engine compartment I used stainless-steel wire ties. Note: As stated, the rescue tape protects both the wires and structure from the stainless-steel wire ties. You will find this is a weight savings, is quicker, and less expensive. My EAA Technical Adviser and the FAA DAR found no fault with this approach.

Cheers!   Stu.

From: "Charlie England" <ceengland7(at)gmail.com>

To: aeroelectric-list(at)matronics.com

Sent: Wednesday, October 11, 2023 2:46:27 PM

Subject: Re: Wire Installation Guidelines



      Or at least not 1 (at least as stated),       for the reason given in 2. 

       Adel clamps are the traditional way, but there are other       techniques to space the wire away from the structure. 

       

       On 10/11/2023 3:01 PM, mark harris wrote:

     

      	  Quote: 	
		                                    2

         

                    

           

           Sent from Outlook for iOS

       

              From:           owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com)           <owner-aeroelectric-list-server(at)matronics.com> (owner-aeroelectric-list-server(at)matronics.com) on behalf           of Jeff Luckey <jluckey(at)pacbell.net> (jluckey(at)pacbell.net)

           Sent: Wednesday, October 11, 2023 6:55:34 PM

           To: Aeroelectric List           <aeroelectric-list(at)matronics.com> (aeroelectric-list(at)matronics.com)

           Subject: Wire Installation           Guidelines          

       

                           What are the "rules" for             running wires along longerons in aluminum airframes?

           

           

           

           

           I see things like:

           

           

           1. simply ty-rapping the             wire to the longeron every 12 to 18 inches.  I see this             mostly in Experimentals.

           

           2. using an Adell clamp, at             that same interval, for wire bundles and sometimes even for             single conductor.  Typically in certified aircraft and             airliners/biz jets/military helos, etc.

           

           

           

           Back when I was a kid, I             was helping a friend wire a racing motorcycle and ty-rapped             a wire directly to the frame of the bike and promptly got             chewed-out.  Apparently using that installation technique is             verboten because it causes the wire to chafe against the             frame with the high-frequency vibrations coming from racing             engines.

           

           

           

           Which way is "the right             way"?

           

           

           

           

           -Jeff

           

           

           

           

           

         

       

     	
     

   

Virus-free.www.avast.com[url=#DAB4FAD8-2DD7-40BB-A1B8-4E2AA1F9FDF2] [/url]

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Eric Page

Joined: 15 Feb 2017
Posts: 244

Posted: Wed Oct 11, 2023 9:01 pm Post subject: Re: Wire Installation Guidelines

And, if you need to stand the wire bundle off from the structure, just cut a short length of rubber hose (1/4" ID works well) of exactly the length you need.  Pass the zip tie through the rubber hose, around the tape-wrapped structural member, back through the hose, then close it around the wire bundle.



Incidentally, "rescue tape" is just one brand name for common self-fusing silicone tape.  Aircraft Spruce carries it under the "Uni-Wrap" brand, and it's also available generically on eBay or Amazon.  Just search for "self fusing silicone tape."

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