Avionics

Mags wired to Ignition Switch & P909 Alternator Power Wire ( 3 hrs)

Attached Right, Left and Gnd wires for Mag and PMAG to Ignition Switch.  Laced wires to other harness for vibration/abrasion protection.  Replaced P909 Alt Power wire with new P909 now 6" longer and w/  5/16" ring terminal on end to fit ANL 60amp Fuse Block bolt on inside firewall on LH side.  Routed Alt Fld & Discrete #4 wires along P909.  Removing and re-installing adel clamps on engine mount and engine was a bear !  (1st time was prior to engine installation -- soooo much easier to access)  Per alternator mfg'er drawing, torqued the 6mm output terminal to 50 in-lbs.

reference for attaching Mag wires and grounds

Mag wires attached & laced to other harness (there's at least 1"
clearance to alt air cable, but pic makes it seem close to wires)

Alt Power wire installed.  Alt Fld and Discrete #4 wires
routed to connector plug on alternator

Avionics

J243 Connector and Mag Wiring ( 4 hrs )

Connected J243 to Garmin GEA24 on RH sub-panel after splitting "Tach Sensor Mag" (connects to pin #6 on PMAG) & "Manifold Press" plus adding "Discrete #4" wire routed through RH Firewall hole (encompassed in nylon sleeve).  Then other wires from J243,  "Fuel Flow Xducer", "Oil Temp", "Oil Press", and "Fuel Press" along with "Main Amps" routed in separate nylon sleeve through LH Firewall hole (except "Main Amps" stays inside to be connected to Shunt).   Installed left Mag's "P-Lead-L" wire along with "Contactor Relay" both from LH panel area through center to LH Firewall hole.  Also from LH panel area, installed right PMag's "P-Lead-R" (connects to pin #4 on PMAG) wire along with "PMAG 3A" wire (connects to pin #5 on PMAG) and "Alt Field" wire.   Rec'd from Stein Air new P909 Alternator Power Wire with 5/16" terminal and 6" longer, so routed through RH Firewall hole.   This will fit 5/16" bolts on 60 amp ANL Fuse Limiter Block [soon will mount to inside of LH Firewall].   I believe I may now have all the wires and cables passing through the firewall.  Whew !

Garmin GEA24 J242 & J243 connectors w/sensor wires
passing through firewall.  Yellow highlights "Discrete #4"
wire added into nylon sleeve.

LH firewall exit...yellow arrow.

overall pic showing lots of wires to route and
connect on firewall side!

Reference wire routing through Firewall:

LH Firewall hole:

• Prop Control cable
• Alternate Air cable
• P212  Battery Power Wire  (ref section 43-04)
• (4) thermocouple wires for EGT 2 & 4, CHT 2 & 4. (from J242)
• P-Lead L (to left Slick Mag)
• Contactor Relay
• Fuel Flow Xducer  (J243)
• Fuel Press Sensor (J243)
• Oil Press (J243)
• Oil Temp (J243)

Also "Main Amps" wire routed to inside LH firewall to connect to Shunt. 


RH Firewall hole:

• Mixture control cable
• Throttle cable
• P909 Alternator Power Wire  (ref section 43-12)
• Discrete #4 (to white wire at alternator plug)
• Alt Fld  (to red wire at alternator plug)
• (4) thermocouple wires for EGT 1 & 3, CHT 1 & 3. (from J242)
• P-Lead R ( to pin #4 PMAG on right)
• PMAG 3A (to pin #5 on PMAG)
• Tach Sensor Mag  (from J243, connects to pin #6 on PMAG)
• Manifold Press Sensor (from J243)

Avionics

Ground Plate and GEA24 J242 ( 3 hrs )

Torqued 5/16" bolts (one brass, other SS) attaching ground plate/"forest of tabs" to inside of firewall.  Nancy helped wrench from outside while I crammed myself under dash to tighten from inside firewall.   Installed clamp to guide harness.  Laced 3 or 4 wires to each other near terminals for better vibration support.  Also installed connector GEA24 J242 (temperature sensors) to RH subpanel.  Slipped nylon sleeve protection on wires, routing odd # sensors through RH firewall hole ( EGT1 & 3, CHT1 & 3) and even # sensors through LH firewall hole (EGT2 & 4,  CHT2 & 4).  No pics yet...

ground plate bolted ton inside firewall. 

Highlighted lacing of wire into groups ( 3 or 4 tied together)

Outside firewall:  part #P25 (battery negative cable) now
anchored directly to brass bolt, vs 6 inches separately to left. 
Battery box is just below.

Avionics

Forest of Tabs ( 2 hrs)

Crimped 13 blue (14-16 ga) Faston terminals onto 25 black ground wires:  (2) 18ga wires at each terminal, (20) 22 ga wires with two at each terminal, and (3) 22 ga wires at one terminal, creating 13 total terminals.  Connected to the 20 tab ground plate.  Used nylon sleeve to protect bundle, plus added black heat shrink tubing at each terminal for some stress relief adjacent to terminal.  Pending tying several wires to each other to provide better vibration support.

Avionics

Forest of Tabs ground plate on Firewall ( 1 hr )

Started to mount "forest of tabs" grounding plate to inside of LH Firewall area.  Drilled two holes for 5/16" bolts (used unibit to enlarge 1/8" pilot holes).  Started adding Faston terminals to 25 black ground wires (two are 18 gage, 23 are 22 gage).

positioned holes & drilled for 5/16" dia mounting bolts.
One is brass and connects to battery negative
cable, other is SS.

Avionics

Circuit Breaker re-visited and Canopy Release ( 3 hrs )

Last week discovered Cabin Lights CB didn't have a wire connected.  Stein Air quickly made appropriate wire w/ terminal & labels, plus provided lacing material and a "Menda Harness Wire Threader" tool (so I could thread wire through already completed laced harnesses) which I rec'd Monday.  So, simply removed CB panel, inserted wiring all the way back to LH side along with other lighting wires (to connect to LED strip under glare shield).   Also used unibit to enlarge hole in IP to 0.50".   Installed SB500-06 in IP so canopy release handle slides through plastic bushing.   I also rec'd order from Stein Air for "forest of tabs" ground plate, faston connectors, plastic protection sleeve.  Next task is to add to inside of firewall.

snap bushing installed for canopy release handle

received parts to install grounding plate on firewall

Firewall Forward Kit

Alternate Air Control Cable ( 1 hr )

Installed Alternate Air Control Cable (emergency opening in air plenum in case air filter is blocked)  per Sect 50-04, Steps 2-10.   Good instructions helped insure operates well.

hardest steps were installing adel clamp attached to
adel clamp on oil line.