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.