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Date: Mon, 12 Sep 2005 11:44:40 -0600
From: Bob White <bob@bob-white.com>
To: "Rotary motors in aircraft" <flyrotary@lancaironline.net>
Subject: Seals for Coil Connectors from Waytek
Message-Id: <20050912114440.96fe4c7c.bob@bob-white.com>
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This info is for those of you who have purchased coil connectors from
Waytek.

Waytek sells a dark red wire seal for the connector, p/n 39006.  This
seal is for wire with an OD of 0.080 - 0.112 inches.  They are made for
16 ga. wire with PVC insulation.  

The diameter of Tefzel (Mil 22759/16) wire is:

  16 ga.  0.077 - 0.081
  18 ga.  0.069 - 0.073
  20 ga.  0.058 - 0.062
  22 ga.  0.050 - 0.054

The 16 ga. Tefzel is marginally within range of these seals, but other
seals are available:

  drk red  0.080 - 0.112, don't need wire this big for these connectors
  white    0.063 - 0.085, good for 16 ga. and 18 ga. Tefzel 
  blue     0.051 - 0.067, good for 20 ga. and 22 ga. Tefzel

There is also a tan seal (it looks orange to me) that would work on 24
ga. wire, but 24 ga. is too small, and for some reason these seals cost
6 times as much.

I don't think this is a big deal.  The 18 ga. wire still makes a fairly
snug fit in the dark red seals, but 20 and 22 ga. doesn't really seal.
If you haven't made up your connectors yet, and would like seals for
smaller wire, I have plenty of the blue and white ones.  Let me know
which ones you want. $2 for a set of 16 including postage.  Otherwise,
you could dab a little RTV in the back of the connector to seal it.

Crimp info:  I purchased the hand crimp tool designed for these
connectors.  Here are the crimp instructions from the catalog:

* Hand crimp tools are designed for repair, prototype, or low volume
  usage.

* Solder with resin core solder to guarantee crimp intergrity(sic).

I don't know if they don't trust their crimp tool to do the job or
what, but soldering shouldn't hurt anything either.  The wires are well
supported by the seals to prevent any vibration problems.  I've also had
pretty good luck crimping the wire with the same tool I use for Molex
connectors and carefully bending the tabs around the seal with long
nose pliers.

Bob W.


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