Avionics

P Mag connection ( 4 hrs )

While preparing to connect "P-Lead R" to right Mag, discovered statement in E-Mag install guide to separate plug leads.  Contacted Trent at E-Mag, who said up to 5" can be bundled, but more will cause induction coupling.  So....spent couple hours revising all lead wires for P Mag using the recommended 1/4" silicone tubing on cable ties to create separators.  Next, connected P Mag per p. 26 schematic in Install Guide and Stein Air's schematic:  "P-Lead R" to Pin 4, with shield wire connected to Pin 1 as ground (added separate wire from engine stud nearby also to Pin 1)  This creates 3 ground paths including P-Mag itself bolted to engine case.   "P Mag 3A" connected to Pin 5, and Tach Output (white wire only) connected to Pin 6.   Finally, aligned blast tube to insure directly on "neck" area of P Mag per Install Guide.  Wrapped oil line with silicone tape (red) prior to applying cable ties.

revised so P Mag leads are separated...RH side

note in E-Mag install guide.

LH side

LH side.  Only minimal contact at cushion
clamps, far less than 5" 

Pin 1, 4, 5 and 6 connected.
Jumper was pre-installed between 2 and 3.

Pin 1, 4, 5 and 6 connected.
Jumper was pre-installed between 2 and 3.

connector re-installed. Ground terminal "loose"
at stud at unused aux drive...for now. 

p 26 schematic in E-Mag Install Guide for P Mag connections 

Blast tube positioned directly blowing on P Mag
"neck".   Red silicone tape protecting Oil Line

blast tube positioned per E-Mag
instructions 

Avionics

Wiring to Fuel Flow Transducer ( 2 hrs )

Connected "red cube" Fuel Flow Transducer (Electronics International FT-60) to wires from GEA24 J243.  Stein Air's Chris confirmed they recommend using the OLC-1 connectors supplied with transducer.   I staggered the 3 connectors to nest for a tighter package.  Used layers of heat shrink tubing followed by wrapping with silicone tape, then cable tied into bundle with CHT sensor wiring.

Instructions for OLC-1 connectors... 
Testing alignment with sample of wire

wrapped with silicone tape, prior to bundling with CHT wires

cable tied to bundle with CHT wiring

Avionics

Mag P-Lead, Oil Temp, Fuel Pressure, Oil Press sensors connected ( 3 hrs )

Completed installation of P-Lead and gnd wire to LH Mag.  Connected Oil Temp sensor and bundled wires w/ P-Lead.  Soldered Fuel Press and Oil Press sensors at LH firewall, leaving extra lengths (just in case require re-do, etc).  Wrapped engine mount tube with silicone tape for protection, then cable tied "loops" of sensor wires to tube.

top view showing wire routing to LH Mag & Oil temp sensor

Add caption

first pressure sensor wiring soldered
connections with 2 layers heat shrink tubing

both press sensors connected.

silicone tape over engine mount tube, then cable tied
 "loops" of  wiring 

nested wiring and secured with cable ties

 

Avionics

Mag P-Lead, etc ( 3 hrs )

Attached two -12 size cushion clamps to engine mount near LH firewall and Left Mag to route wires for Fuel and Oil Pressure sensors, Oil Temp sensor, and P-Lead for Mag (combined w/ a -4 and -3 clamp).  Clamped wires along upper rear engine mount tubing.  Referenced Stein Air's schematic for GEA24 J243 connector for wire to wire connections.   Josh Swenson at Stein provided tip for connection of P-Lead with ground wire:  After uncovering braided shield wire,  push braid backwards to open weave, then pull single wire for P-Lead out of open mesh ( I used a toothpick).  This enables the braided shield to become a "wire" to directly crimp on ring terminal for gnd connection (instead of soldering a wire to section of braided shield).  After practice with couple pieces, I decided this worked well for the P-Lead.  No soldering, only #10 ring terminals added to ends.   Included layers of heat shrink to each wire.  Even remembered to include the MS25171-1S silicone terminal cover for the P-Lead post.

routing wire from LH firewall opening

P-Lead & ground connections ready to
  attach to LH Mag.   After pic, slid
2 layers of heat shrink  over "joint"

test: pulling center wire out
through braided shield

Avionics

Alt Field, Discrete #4 and Contactor Relay" connected ( 3 hrs )

Connected "Alt Fld" wire (from Master Switch position 3) to Alternator red wire (from gray  connector on alternator for Alt Enable Field Switch).  Connected "Discrete #4" wire from GEA24 J244 connector to white wire at Alt (connector on back of Alternator)  - to provide indication Alt output "OFF".  Per Stein Air's recommendation, I soldered wires instead of using crimped splice joints.  So most of time spent practice soldering.   Covered joints with two layers heat shrink for better toughness, and the extra lengths were doubled up and secured with cable ties to P909 Alt Pwr wire.  Added spiral wrap for extra protection (not in pic below).    Next, connected "Contactor Relay" wire from Master Switch (position 6) to Master or Main Battery Contactor Relay on firewall.  Crimped ring terminal on the Wht/Brn wire. secured to post along with ES Diode Master.  Used layered heat shrink at crimp, then covered this single wire with small dia spiral wrap all the way to firewall opening.

Doubled extra length of wires after soldering, covering heat shrink. 
After pic, covered with spiral wrap

view from below...  secured "Contactor Relay" wire to battery 

cable on way to firewall opening

Avionics

Ignition Wiring (  3 hrs )

Received re-done Floormats and Baggage Floor from Abby at Flightline Interiors.  Much improved fit -- Yay!  [ Note:  after initial trial fit Oct 23 I determined the width of the floormats and baggage area were from 3/8" to 7/8" short - leaving considerable gaps.  Several pics of other RV14's with same interiors showed essentially no gaps.  Abby readily agreed to remake them for me, explaining the templates haven't changed, but a new person may have incorrectly made mine ]   Completed adding cushion clamps to LH side top ignition wires.  Since the red silicone wires for PMAG are larger dia, needed to upsize each from 1-2 steps (ie WDG 4 --> 5 w/ single wire, and WDG 6 --> 8 for two wire locations.   Bundled Mag (bottom cyl 1& 3) with PMAG (top cyl 2 & 4) together behind engine -- another challenge to reach.  I think I can see the light at the end of the wiring tunnel!

baggage floor...fits great now.

LH floormat fits perfectly

Same for RH floormat.   

top ignition wires on LH side.  Larger clamps needed
for silicone wires provided w/ PMAG

PMAG ignition wires under Mag on LH side

behind engine, under oil filter.  bundled Mag wires
 going to RH side (bottom) with those from PMAG
going to LH side (top)

Avionics

CHT sensors LH side ( 2 hrs )

Completed LH side CHT sensors for cyl 2 & 4.   Torqued all four to 28 in-lbs per Alcor Tempest instructions.  Installed MS21919WD7 cushion clamp to route top ignition wires for cyl 2 & 4 from PMAG (extra clamp just rec'd from Aircraft Spruce)

Yellow dots trace thermocouple wires with connections under
black fiberglass sleeve.  Arrows point to CHT sensors.

Additional clamp on engine mount to secure PMAG
ignition wires (red) for top plugs on cyl 2 & 4.

Avionics

CHT sensors installed ( 2 hrs )

Installed CHT sensors ( Garmin part # 494-70000-00, Type K, bayonet) in cylinders 1 & 3 on right side.  Crimped on #4 ring terminals to match pre-terminated sensor wires with screw/nut assembly.  Layered heat shrink tubing followed by fiberglass sleeve (provided w/ sensor) to provide stability/protection.  Most of my time was exploring where best to cut terminal wire at each location.

CHT sensor "kits" with instructions

Completing CHT #1 connection (#3 connection is inside
 fiberglass sleeve I'm holding aside ) prior to heat shrink tubing

Loops for strain relief.   Also must keep away from
exhaust tubes,  yet to be installed.

Challenge to accommodate engine movement on rubber mounts
while keeping wires away from edges and hot exhaust.

Avionics

Ignition Wire Routing ( 2 hrs )

Routed ignition wires from Mag and PMag to plugs, along with thermocouple wires for CHT and EGT sensors.   Completed RH side, but required revision to cushion clamps to accommodate larger dia plug wires from the PMAG.  Started LH side, but needed to order larger size cushion clamp to fit the PMAG wires.

RH side:  two cushion clamps (1 for PMAG

top plug wires, 1 for bottom MAG wires)  

Not ready to connect to spark plugs, since desiccant plugs

(yellow tick marks) will remain for awhile.  Ready to install 

CHT sensors, but waiting to install exhaust - so I'll install 

EGT sensors later. 

Avionics

Complete installation P909, ANL Fuse Limiter, Shunt & P912 ( 2 hrs )

Torqued terminal bolts and applied torq seal.  Added cushion clamp to P912/P909 wires and some spiral wrap protection.   Plus cable ties to stabilize "Main Amps" wire with P912/P909.

Torqued terminals and applied torq seal.  Added cushion clamp,
spiral wrap, edge protection and cable ties.

"selfie" while deep under dash trying
 to take pic of upper firewall

Avionics

Shunt and ANL Fuse Limiter ( 4 hrs )

Mocked up installation design of ANL Fuse Limiter Block w/ 60 amp Fuse and Shunt for mounting inside LH Firewall (up high).  Used template to drill holes in SS firewall, then pre-assembled as much as feasible - since I knew access way up under the dash would be difficult.   Crimped ring terminals to "Main Amps" wire from J243 connector, with couple layers of heat shrink to improve vibration resistance.   Mounted both Limiter Block and Shunt to Firewall with short 4" wire between (Stein Air constructed due to larger terminals).  Fastened P909 (Alternator Pwr wire) to Fuse Block and P912 (Battery Pwr) to Shunt.  As expected, the last steps "under the dash" was challenging!   Final wire routing, clamping and protection yet to do....

Mock up using template of LH Firewall corner.

Pre-assembled as much as feasible while easy to reach !

Final check of arrangement

Another milestone.  Just final wire routing,
protection and clamping needed.

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)