Wiring Panel

This blog covers the wiring behind the panel

Overview
The work to convert all the wiring schematics into the physical world has now to be undertaken. Without detailed design work and drawings a lot has to be left to the imagination, while living in the hope of finishing with a product that appears to have a small amount of intelligence applied.

The primary goals set for the installation : -

1 - The panel must be removable by disconnecting plugs. 

2 - Weight to be kept to a minimum.

3 - Wiring to be in a orderly  and logical 

The channel was secured at the firewall and the lower panel using four [4] M3 rivet nuts at both ends. The lower rail that the panel is mounted on had a series of holes drilled to align with the front mounting screws of the channel.

The side Z panels for mounting other hardware were now installed and secured with self tapping screws. These should have been installed much earlier as access for the fixings was a real issue requiring the removal of the mounting angles for the panel cover.

T panel installed - undercarriage terminal strips on left with
first of the AMP plugs installed for the intercom. Additional plugs will be
installed to connect to the breaker / switch panel 

RS 232 connectors mounted in channel for tacho,manifold pressures and AOA [LHS]
Cables for engine instruments shown on RHS connected to power bus

Note: The mounting panels are screwed only to allow removal / replacement in the event of a major change at some future date. The T mounting was necessary to provide adequate mounting points for the electrical hardware

Component assembly center support
Master terminal strip would have been better at six studs
with the shunt relocated

RS232 Connections
While the UMA instruments selected had a RS232 plug, a number of other instruments did not namely the AOA indicator, trim indicators and assorted lights.

Punch openings and RS232 connectors
Note the flattening of the ferals after installation

As supplied - LHS

Center support punched to allow the mounting of the RS232 connector with incorporated terminal strip. Each wire was fitted with a ferrule to protect the wire when clamped into the strips. The hex mounting nuts supplied with the terminals were removed and replaced with longer one to allow fixing onto the center channel.

The LED indicators has a RS232 socket soldered onto the factory wires and supported with a 0.040'' 2024-T3 brackets fixed to the panel using 3M automotive trim tape.

RS232 plugs LED / AOA indicator

These brackets carry the load and provide strain relief for the solder connections with a short cable connecting the instrument to the channel connectors as outline above.

Firewall Penetrations

IP68 Glands

Many of the cables from the engine instruments are required to penetrate the firewall. Though there are many systems around these are large, expensive and not available in Australia. With our main enemy being fumes, brass IP68 glands were sourced from JayCar and then installed with the seals located on the inside face placing the open base at the firewall side. The glands are tightened around the cable with the open face to be sealed with high temperature red silicone. 

Each cable is tagged with its cable ID at the exit. This is to assist troubleshooting and locating to correct cable to hook to the sensors.

Firewall penetrations IP68 glands
All labels printed with the Dymo printer on heat shrink tube

Note: The pitch chosen was a little tight and this builder would recommend spacing to suit your ring spanners. 

Starter Solenoid
The starter solenoid was mounted adjacent to the master positive stud located in the firewall and connected with a brass bus. This will have a insulated coating applied at final installation with a insulated coating applied to the brass bus.

Starter solenoid connected to positive battery stud
connected with 20 x 1.5 mm brass bus

Comment
Kaos appearing to ease as each wire is terminated with the largest issue just converting the schematics into real world wire and seeing how to have them interact with each other.