Avionics table, first avionics wiring! | 1.14.2021

Started off the afternoon with a few parts coming in. First up is the Airflow Performance throttle arm. The stock throttle arm (or at least whatever is stock on a PA28R-200) is too tall when fit to the Velocity, so I found this low profile arm that's a perfect fit.

Low profile, with stock in the background

Next up were our custom engraved Honeywell AML34 rocker covers. I had ordered these a while ago from Aircraft Engravers and told them I was in no rush, so they could fit our switches in whenever. Took about 2 weeks to ship, then USPS lost them for like a week and a half.

I have to say, these came out absolutely beautiful. We had them engrave white, painted rocker covers, so that when they're backlit, the light will shine through the white lettering. Highly recommend using Aircraft Engravers.

Top switches will go in overhead panel, bottom switches will go on the main panel

Once that was all done, I set out to Home Depot to figure out how I was going to build a large table for the upcoming avionics and upholstery work. After considering building legs, I looked in the sawhorse section and found the ones below that have a channel in them to accept a 2x4 to make a jobsite table. Figured once they're done here, I have a nice set of sawhorses; plus I didn't have to build a table. Win/win.

Table top is 4'x8' particleboard. Basically no flex once on the 2x4s.

I couldn't just set up the table then do nothing, so I started work on the GEA24 engine sensor harnesses. Figured this would give me a head start on figuring this whole "wiring" thing out, without having to dive into the entire harness. These are sort of separate, independent harnesses.

Needless to say: there's a ton of prep work and information going into these, and to be honest I don't feel that there's a great resource for it online. I'll be posting an in-depth write-up on harness fabrication at some point, but that time is not now. I think I might make up a presentation for the local EAA chapter. I think it would make a great topic.

For now, here's some pictures:

Sensor harness with shielded wire terminated via solder.

Finished thermocouple harness. This is for the EGT and CHT sensors.

Showing the pins

That's all I have for now. Thanks for tuning in!

- Jeff