Message-ID: <3746BAA3.1189E3CB@regandesigns.com>
Date: Sat, 22 May 1999 07:09:39 -0700
From: Brent Regan <brent@regandesigns.com>
To: lancair.list@olsusa.com
Subject: Connectors
References: <19990518045321.AAA12475@truman.olsusa.com>
Mime-Version: 1.0

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The BEST connector is no connector. It has been my experience that if there is
going to be a problem with an electrical circuit it will most often be in the
connector. I hate connectors. I really hate cheap connectors. I have designed
electro mechanical hardware that has been to the bottom of the ocean and into
space and I could retire on the time and money I have spent chasing down faulty
connectors.

The best, lightest, most reliable connection is solder and heat shrink. Sure, it
takes a couple of minutes more if you have the rare occasion to take an aileron,
or whatever, off, but you save the time and cost of installing the connector plus
the time you will spend looking for that corroded pin or fatigued conductor.

If you must use a connector, these are the features it should have:
Gold plated contacts
Multiple conduction paths on each contact
Solder or cylindrical crimp
Good mechanical strain relief
Dust and moisture seal
Mechanical retention

"Features" you don't want:
Tin plated contacts
"Leaf" type crimp
Available at an auto parts store
Faston anything
Friction retention

The AMP Circular Plastic Connector (CPC) series is probably your best connector
for the dollar.

Some other Do's and Don'ts:

Do  use Tefzel insulated stranded wire
Don't use the cable or Fastons you get from Vision Microsystems
Don't use the cable you get from MAC
Do use shielded Tefzel insulated cable from your avionics shop
Don't use mechanical strippers, they nick the conductor, planting the seed of
failure.
Do use thermal strippers
Do use a low wattage, regulated soldering iron
Do restrain and support the wiring harness and connectors
Do make a schematic of your airplane


Keep it simple and your reward will be reliability.

Regards
Brent Regan


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