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  #1  
Old 06-23-2022, 09:19 AM
KHeidorn KHeidorn is offline
 
Join Date: Nov 2013
Location: Heber City, UT
Posts: 124
Default Importance of Wire Support

My flight ended with a low voltage warning.

The "B" lead attached to the alternator was not supported sufficiently and over 250 hours of vibration caused the terminal to crack then arc.

Certainly, could have been much worse.



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  #2  
Old 06-24-2022, 01:44 AM
kiwipete kiwipete is offline
 
Join Date: Oct 2007
Location: Birmingham United Kingdom
Posts: 482
Default

Ken

Glad to see that you only had a burnt wire, it could have turned out much worse.

Quick question- did you have a circuit breaker or inline ANL fuse on the B lead,For this exact scenario? If so it it work? Or was the wire just arching across the crack in the terminal fitting?

Regards

Peter
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Last edited by kiwipete : 06-24-2022 at 01:55 AM. Reason: Typo
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  #3  
Old 06-24-2022, 06:13 AM
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Walt Walt is online now
 
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Default

Looks like a rather large gauge cable, the larger the cable the stiffer it is.
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  #4  
Old 06-24-2022, 10:14 AM
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Draker Draker is offline
 
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Location: O61
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Default

Did the wire fall out of the crimped terminal? I've already had one of my thick 6-ga wires fail in this way (did not pass the tug test during my pre-airworthiness condition inspection). Now I'm doubting all my crimps. Used one of those crimp tools you whack with a hammer. Wish there was a better way to secure large important wires to ring terminals.
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  #5  
Old 06-24-2022, 10:19 AM
Larry DeCamp Larry DeCamp is offline
 
Join Date: Apr 2010
Location: Clinton, Indiana
Posts: 1,259
Default Draker suggestionm

Any local automotive electric shop has dies and tools for a secure job. They do eveything from bulldozers to fire trucks where where reliability counts.
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Last edited by Larry DeCamp : 06-24-2022 at 10:22 AM.
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  #6  
Old 06-24-2022, 10:19 AM
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jneves jneves is offline
 
Join Date: Aug 2021
Location: Livermore, CA
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Default

Quote:
Originally Posted by Draker View Post
Did the wire fall out of the crimped terminal? I've already had one of my thick 6-ga wires fail in this way (did not pass the tug test during my pre-airworthiness condition inspection). Now I'm doubting all my crimps. Used one of those crimp tools you whack with a hammer. Wish there was a better way to secure large important wires to ring terminals.
The hammer type are very prone to not getting a solid crimp. The best low cost options are one of these from Amazon.

https://www.amazon.com/IWISS-Termina...13145091&psc=1

https://www.amazon.com/Hydraulic-Cri...730998421&th=1
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  #7  
Old 06-24-2022, 11:53 AM
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FuturPilot FuturPilot is offline
 
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Location: NW MN
Posts: 83
Default Crimp ?

Any reason we can't crimp then solder the connectors?
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  #8  
Old 06-24-2022, 12:16 PM
Freemasm Freemasm is online now
 
Join Date: Nov 2017
Location: Orlando
Posts: 812
Default A question for the uninformed, please.

I'm not deep into wiring yet so I haven't geeked up to the required levels yet.

The only reference I've found regarding wire support/secure intervals is not to exceed 24 inches. Any of you better versed types find anything different? It would be appreciated and probably save me study time in the future.
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  #9  
Old 06-24-2022, 01:14 PM
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Draker Draker is offline
 
Join Date: Jun 2016
Location: O61
Posts: 706
Default

Do those tools require special terminals? I've been using these types of terminals from DigiKey: https://www.digikey.com/en/products/...7076-ND/287757

Quote:
Originally Posted by jneves View Post
The hammer type are very prone to not getting a solid crimp. The best low cost options are one of these from Amazon.

https://www.amazon.com/IWISS-Termina...13145091&psc=1

https://www.amazon.com/Hydraulic-Cri...730998421&th=1
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  #10  
Old 06-24-2022, 01:18 PM
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MacCool MacCool is offline
 
Join Date: Aug 2020
Location: central Minnesota
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Quote:
Originally Posted by FuturPilot View Post
Any reason we can't crimp then solder the connectors?
I have been told by people smarter than me that solder imposes a level of brittleness to a connection that increases its likelihood of fracturing under vibration stress.
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