Unlike closely held inventions and processes unique to individuals, knowledge and
understanding are commodities that GROW in value the more they are shared. While
the techniques and style of sharing may vary from teacher to teacher, the fundamentals
are pre-existing and without ownership. If anyone finds an opportunity to expand
the universe of dissemination for ideas offered on this website, you are free to reprint
any materials published here. All I would ask is that reprints be published without
modification and properly cited as to source.
If anyone detects a variance from facts or physics in any materials published on
this website, I'd certainly like to hear from you. These pages are not intended
to be the gospel according to Bob Nuckolls but a repository for some of the best
aircraft design, fabrication and operating techniques to be found anywhere. Words
found on these pages are representative of many sources of information not the least
of which include our readers. Comments and alternative views from anyone are always
welcome.
1/25/17 |
"Getting Started." If you're just beginning to plan your attack on the
electrical system, here's an article to jump-start the process.
Economics of Weight Reduction a piece which encourages
builders to ascertain the REAL value of weight reduction in their project.
"Avionics Master Switches: Really Necessary?"
"What's all This Battery Isolator Stuff About Anyhow?" Sport Aviation, December 1995, Page 87
"What's all This Failure Tolerance Stuff Anyhow?"
New Z-19RB. Rear Mounted
Battery version for single alternator automotive conversions.
Click here for second sheet.
"Low Cost Ground Power Jack for Your Airplane" Sport Aviation, November 1997, Page 85.
An All Electric Airplane on a Budget
EXP-Bus a review of the on-line advertisement.
EXP-Bus Discussions on the Net
Vacuum Systems vs. All Electric - a thread on systems that suck.
All Electric Panel - a list server thread . . . .
What's all
this DO-160 Stuff Anyhow? A brief tour of RTCA DO-160 . . .
A common sense approach to deciding if an electro-whizzy is going to survive
and perform as intended in an airplane.
Nipon Denso modifications
for external regulation. Appeared in November 2019 Kitplanes . . . a well illustrated
minimalist approach to modifying an ND alternator for external control.
Nipon Denso modifications
for external regulation. Appeared in September 2009 EAA Experimenter. Another
approach to modifying an ND alternator for external control.
Click here for an explanation of failures
of internally regulated alternators when fitted with crowbar OV protection and a
b-lead disconnect contactor.
What about those built-in regulators?
Know your Charging System . . .
an often cited, not-so-helpful self-help document on the 'net.
Alternator Testing with a
temporarily installed test regulator.
PM Alternator Noise a collection of 'scope
traces that illustrate exemplar noise signatures from single-phase, permanent-magnet
alternators.
To lithium or not to lithium, that IS the question.
How does capacity correlate with charge voltage for LiFePO4.pdf
Myths of Multiple Battery Installations
Battery Replacement - a plan for throwing in the towel . . . a
capacity test fixture.
Click here to explore the question, "How
bad can an alkaline battery be?"
Everything you ever wanted to know about RG
batteries but were afraid to ask. . .
"No Juice" a short piece on RG batteries which
appeared originally in Aviation Consumer, Februrary 1, 1995. and
updated 4-15-98.
Click here
for compilation of battery maintenance techniques including output conditioning
for solar cells to prevent over-charging.
"Batteries, a list server thread."
"Ni-Cad Cell 'Memory' - Fact or Myth" Here's an
explanation about a mis-interpreted behavior of Nickle-Cadmium physics in small
re-chargeable cells. Written by "Mr. Battery" hisself . . . Isidor Buchmann.
Battery Charger/Maintainers Overview
DIY Project: Roll-ur-Own Crowbar OV Module. One of the parts in the earlier article has become obsolete. This new piece uses more generic and readily available components.
DIY Project: Click here for the
data package on a do-it-yourself low voltage monitor. This circuit is identical to the
one used on our LVM-14 Loadmeter/Voltmeter and LV Warning system. All of the parts
can be acquired from Digikey.
Failure Detection and Annunciation, an
article on current monitoring techniques to annunciating failures of lamps, pitot heaters,
etc.
Building your own VHF Comm Antenna.
Morris Com Loop Antenna for
fiberglas aircraft.
Bob Archer: Antennas for Aircraft
External Antenna Extension for your Hand-Held
Instructions for RCT-2 Coax Crimp Tool
Check out photo #1
and photo #2 suggestions for
routing external antenna coax to your hand held radio.
Comic Book on Coax Cable Connector
Identification illustrates several styles of BNC coax connectors . . .
Click here for Bob's Shop Notes
on a low cost alternative to one-piece, right-angle coax connectors.
VOR/LOC Antenna BALUN Fabrication
made easy.
Huggins: Coax Velocity Factor in Baluns
Confused about microphone jack wiring? Click here for a page from Bob's Shop Notes DIY Project: Audio Isolation Amplifier
and Revision K to the ECB Assembly.
Stereo Music in your Airplane? Here's a set of wiring diagrams
that illustrate audio wiring to integrate stereo music sources with
monaural aviation audio sources. The diagrams are specific to the Micoair 760
VHF transceiver and exemplary of other combinations of avionics accessories. This
data package also shows you how to assemble and install your own audio isolation
amplifier in either stereo or monophonic configurations.
Click here to download.
D-Sub Pin Extraction Made Easy.
Conducting High Currents through D-Sub Connectors
Bob's Shop Notes: A comic book
on installation of open barrel pins on Waldom Molex, AMP Mate-n-Lock, and
D-Subminature connectors using our BCT-1 or similar crimp tool.
Bob's Shop Notes: Soldering D-Subminiature Connectors
Fuses & Breakers . . . to fiddle or not to fiddle, that is the question . . . .
"Fuses or Circuit Breakers?" Sport Aviation, March 1993, Page 86.
New comic book on breaker failures. "Yes
Matilda, there are breakers that I would not recommend for airplanes."
Click here for
Bob's Shop Notes on the differences between ANL current limiters and JJS/JJN
series fuses.
Comic Book on Fusible Link Fabrication shows step by step procedure for building 22 and 24AWG fusible links. . . . .
Shower-o-Sparks
Magneto Wiring. Here's a way to wire magnetos fitted with retard breaker
points and still use low cost, panel friendly toggle switches for control.
Magneto Timing A compendium of articles
and pictures on magneto timing tools and techniques.
Gauging Pitot Heater Performance - A study in fundamental heat physics.
Paul McAllister: Anatomy of a Lightning Strike
Minimum Instrument and Equipment Requirements for Powered Amateur Aircraft
Pengilly: How to Choose an EFIS Pt1
Pengilly: How to Choose an EFIS Pt2
Baker: Static System Checks for OBAM Aircraft
An illustrated discussion about spike catching diodes and how they work.
Low Cost Wig-Wag system using automotive
flasher.
Is my long-term-storage strobe supply likely to self destruct? Check out this piece . . .
Long Term Stability
of Aluminum Electrolytics.
Fine Tuning the Invention Here's a copy of
patent 4696832 on a technique for treating the surface of switch, relay and connector
contacts to reduce the effects of environment on the mating surfaces.
Dark-n-Stormy-Night Stories A
good example of how stories intended to educate and illuminate the inner secrets of
aircraft operation fall short . . . especially when it comes to electrical systems.
Never Again - The Saga Continues.
One of thousands of stories over the years that shows were we need to be going with
our airplanes and their systems.
"Switch Ratings - What Does it all Mean?"
AeroElectric Connection drawings depict a mixture of progressive transfer switches
by Honeywell-MicroSwitch and Carling (who makes the S700-Series switches stocked at
B&C). Click here for a document on
switches that describes the different numbering for the progressive transfer
switches.
The big, red, split-rocker switch popularize by the type certified airplane
guys is easily replaced by a less expensive, progressive-transfer toggle switch
that mounts in a ROUND hole and looks like the rest of the switches on your panel.
Click here for
the interchangeability data.
DIY fancy handles for flap and gear
extension switches.
"Let's Talk Starter Solenoids"(230K Illustrated).
Schematic for flap system using permanent magnet motor includes dynamic braking, options for limit switches and second switch for "back seater" . . . .
When Pitch Trim Systems Turn Ugly a
discussion on the value of a Plan-B for misbehaving motors that drive flight controls.
RayAllen (MAC) trim servos are
fitted with a short bundle of small wires. This edition of Bob's Shop Notes:
offers an easy connector solution
for dealing with those frustrating little wires.
Click Here for a .pdf file on Ray Allen (MAC)
Servo Trim system using factory Relay Deck. Click Here
for a .pdf file on MAC Servo Trim system with a roll-your-own relay
deck.
"AeroElectric Connection, an Information Service and Guide to Theory, Operation, Design and Fabrication of Aircraft Electrical Systems". 8.5" x 11" 230+ pages. Loose leaf text designed to allow periodic updating with the evolvoing art and technology of building the world's finest single engine aircraft.
MOST of the the work for preparing a nice wirebook for your airplane
is alread done. The following links will take you to a collection of drawing files
done in AutoCAD. TurboCAD version 7 or later will also open, edit, save and print
these files. Copies of TurboCAD can be acquired for a little as $15.
Click here for down-loadable architecture
diagrams in AutoCAD. If you'd like to develop a wirebook for your project that
rivals anything sold for a Learjet there is a collection of
"work in progress" drawings at which you're welcome to download and use as
you see fit.
Part 91 Requirements for Instrumentation in Aircraft.
One-page wire size chart excerpted
from chapter 8 of the 'Connection.
Drill Size Chart converts number, letter and fractional drills to decimal inches . . .
Bob's Shop Notes: CladBoarding - The fast track from idea to proof of concept. This article illustrates one
of Bob's favorite techniques for quickly assembling small to moderately complex electronic circuits for testing.
Bob's Shop Notes: Up-Armoring your Air Conditioner - An ounce of prevention worth a bucket of sweat and a pound of cure.This
article illustrates a technique for minimizing yearly maintenance hassles while keeping your summer cool.
B&C Starters; A net thread . . . .
DIY Starter Adapter for Lycoming Engines
Bob's Shop Notes:
Probing the Current in an ATN Fuse Did you ever want to measure the current
through a plastic fuse in your car, boat or airplane? Here's one way to fabricate
a probe that will let you do just that . . .
Quick and Easy Garage Sale Table
assemble in 30 minutes for about $20. This two-tier table is handy for spreading
out your inventory in the shop during assembly or selling excess inventory in your
post-fabrication garage sale. Knocks down for storage. However, so easy to build
that I sell them along with merchandise at the garage sale for $30. Customer knocks
them down for you and it avoids storage between sales.
Bob's Shop Notes
on crimping tools for solderless terminals, a comparison
of two tools with wide range of cost. An examination of how well they
work.
Click Here for Bob's Shop Notes on coax stripping tools
Wire Strippers - Wire Strippers - Facts and Myths A shop note that explores the
physics of getting that little bit of plastic out of the way so you can get on with wiring
the airplane . . .
Curious as to the accuracy of your hand-held voltmeter?
Here is a schematic for an easily
constructed, precision voltage source that may be used to confirm the accuracy
of your voltage test tool.
"Wire Sizing" Sport Aviation, June 1997, Page 56.
"Adel" Clamps, everything you wanted to know
and were afraid to ask . . .
Keeping track of the wires: Check out this
technique for tagging the ends of wires as bundles are installed in your
airplane.
Here's a picture that illustrates some
important points for installing our S704-1 as an alternator disconnect relay
in permanent magnet alternator installations.
Local Battery Grounds
Bob's Shop Notes on local battery grounding to metallic structure in airplanes.
Integrating Homeless Components into
Airframe Wiring.
Firewall
Penetrations Getting the Wires in While Keeping the Flames Out. A comic
book on a time tested, simple firewall penetration technique for wires.
Click here for robust, low cost option
for wing-root wiring disconnect.
Click here for
Bob's Shop Notes on string ties for wire bundles
Crimp or Solder - the debate just won't die. Here's a critical review of an article that appeared in Sport Aviation. The author advocates a lot of tools and techniques that are in stark contrast to aviation practice and rudimentary physics of joining wires.
Anatomy of a Good Solderless Terminal
Terminal Installation on Copper-Clad Aluminum
"FastOn vs. Ring Terminals . . . What's the Difference?"
"Big Connections - Terminal Installations on Big Wires . . ." Kit Aircraft Builder, Fall 1996
Multiple wires in a single crimp? Sure, why not? Click here for an illustrated Shop
Notes on an easy technique for insuring good results.
Bob's Shop Notes:
"Solder Lap Splicing of Wires" A comic book on high integrity splicing of small
wires in aircraft.
"Jack Tab Soldering,
Bob's Shop Notes on attaching wires to solderable tabs on jacks, switches, etc.
Soldered Lap
Splices" in lieu of bulky, more expensive techniques.
Quick-n-Easy Thermocouple Splicing.
Bob's Shop Notes: "Shield Termination Techniques"
Got a ton of shielded wires and only a few ground pins in the connectors? Here's
an easy way to deal with the task. Bob's Shop Notes:
"Splicing Shielded Wires" A comic book on making a permanent joint between
two shielded wires.
================================
"Wired for Disaster" a critical
review of a Sport Aviation Article.
When is a Good Ground Not? An article on the
fabrication and use of a 4-wire milliohmmeter.
What's the AeroElectric-List About Anyway?
What's all This List-Server Stuff Anyhow?
Back to Basics Testing in Aircraft with
Electronic Flight Instrument Displays
"Spikes and Transient Voltage Suppressors" A list server thread (600K Illustrated).
Recombinant Gas Batteries Everything you wanted to know but were afraid to ask.
"Thermocouples - An excerpt from Chapter 14 of The AeroElectric Connection."
In Flight Fires a collection of articles
on fires aboard aircraft.
Document Hazard Warning Richter says
wiring per the 'Connection can produce "atrocious" results. It would be nice if effort
expended by all individuals concerned with this thread advanced the state of
our art. Sadly, this is not so. Until the offer for open and constructive dialog
is accepted and acted upon, this thread will have to be filed under the Interest
and Commentary section.
"The Future of Amateur Built Aviation - We Need to be Better Than Certified"
"The American General Aviation Technology Experiment: A future for you and me?"
In Memory of Robert L. Nuckolls, Jr.
A Belated Tribute to my most cherished teacher.
Some Observations on Citizenship
Resistance is Futile . . . You will be Assimilated.
How about a comprehensive bone ban treaty?
I'll have a Physics 101, History 201 (hold the War of 1812) and a side of Football? . . .
Logic Man - his condition is deteriorating . . .
Design and Fabrication - Architecture Decisions
DC Power Generation
Annunciation and Warning
Roll your own annunciator
panel by Paul DyeAntennas, Feedlines and Coax Connectors
Audio
Connectors
Circuit Protection
Hour Meters
Ignition
Ice and Lightning
Instrumentation
Interference and Noise
Lighting
Switches, Relays and Contactors
Stories: Dark-n-Stormy Night
Testing
Trim, Flaps and Autopilot
Panels
Reference Documents
A compilation of
frequently asked questions thanks to AeroElectric-List reader L. Holt. This
rather large .pdf file contains a huge data base of questions and answers fielded
on the AeroElectric-List . . . use the Acrobat Reader word search function to quickly
root out answers to many of your questions.Shop and Bench Practice
Starters
Tools
Wiring Techniques
========== How it Works ==========
========== Aviation Interest and Comentary ==========
========== Bob's Miscellaneous Writings ==========
