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.
03/07 |
Roll your own annunciator panel by Paul Dye
Alternator Testing with a temporarily installed test regulator.
Morris Com Loop Antenna for fiberglas aircraft
DIY fancy handles for flap and gear extension switches.
Quick-n-Easy Thermocouple Splicing.
Soldered Lap Splices" in lieu of bulky, more expensive techniques.
VOR/LOC Antenna BALUN Fabrication made easy.
Integrating Homeless Components into Airframe Wiring.
When Pitch Trim Systems Turn Ugly a discussion on the value of a Plan-B for misbehaving motors that drive flight controls.
New Z-19RB. Rear Mounted Battery version for single alternator automotive conversions. Click here for second sheet.
Adapting the Internally Regulated Alternator to Aircraft Here's a brief document describing how to install an interim alternator control and OV protection system in preparation for conversion to a new, AEC9004 Alternator Control System under development.
D-Sub Pin Extraction Made Easy.
"Getting Started." If you're just beginning to plan your attack on the electrical system, here's an article to jump-start the process.
DIY Starter Adapter for Lycoming Engines
Local Battery Grounds Bob's Shop Notes on local battery grounding to metallic structure in airplanes.
"Jack Tab Soldering, Bob's Shop Notes on attaching wires to solderable tabs on jacks, switches, etc.
Click here for compilation of battery maintenance techniques including output conditioning for solar cells to prevent over-charging.
Click Here for Bob's Shop Notes on coax stripping tools
Click here for one-page, .pdf wire size chart excerpted from chapter 8 of the 'Connection.
Click here for Bob's Shop Notes on a low cost alternative to one-piece, right-angle coax connectors.
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
Multiple wires in a single crimp? Sure, why not? Click here for an illustrated Shop Notes on an easy technique for insuring good results.
Click here for the schematic 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.
Noise in the headset? Check out these useful Radio Shack noise filters Click here for a description of two effective, ready to mount, off the shelf filters.
Confused about microphone jack wiring? Click here for a page from Bob's Shop Notes that should help you sort out where the wires need to solder onto the back of your microphone jack . . .
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.
Bob's Shop Notes: CladBoarding - The fast track from idea to proof of concept. This article illustrates on of Bob's favorite techniques for quickly assembling small to moderately complex electronic circuits for testing.
Bob's Shop Notes: Too Many Shields, Too Few Pins. 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: "Solder Lap Splicing of Wires" A comic book on high integrity splicing of small wires in aircraft.
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.
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.
Here's a picture that illustrates some important points for installing our S704-1 as an alternator disconnect relay in permanent magnet alternator installations.
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.
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.
Low Cost Wig-Wag system using automotive flasher.
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.
Bob's Shop Notes: Soldering D-Subminiature Connectors
An All Electric Airplane on a Budget
"Low Cost Ground Power Jack for Your Airplane" Sport Aviation, November 1997, Page 85.
"Big Connections - Terminal Installations on Big Wires . . ." Kit Aircraft Builder, Fall 1996
When is a Good Ground Not? An article on the fabrication and use of a 4-wire milliohmmeter.
Instructions for RCT-2 Coax Crimp Tool
Comic Book on Coax Cable Connector Identification illustrates several styles of BNC coax connectors . . .
Comic Book on Fusible Link Fabrication shows step by step procedure for building 22 and 24AWG fusible links. . . . .
Battery Replacement - a plan for throwing in the towel . . . a capacity test fixture.
Schematic for flap system using permanent magnet motor includes dynamic braking, options for limit switches and second switch for "back seater" . . . .
When Trim Systems Turn Ugly . . . an article that explores risk mitigation for a malfunctioning electric trim system.
Back to Basics Testing in Aircraft with Electronic Flight Instrument Displays
Is my long-term-storage strobe supply likely to self destruct? Check out this piece . . . Long Term Stability of Aluminum Electrolytics.
Failure Detection and Annunciation, an article on current monitoring techniques to annunciating failures of lamps, pitot heaters, etc.
"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.
"What's all this DO-160 Stuff Anyhow?" a brief look at what manufacturers of aircraft electro-whizzies do to demonstrate their products are designed to live in the real world.
"Wired for Disaster" a critical review of a Sport Aviation Article
Paul McAllister: Anatomy of a Lightning Strike
New comic book on breaker failures. "Yes Matilda, there are breakers that I would not recommend for airplanes."
Click here for an explanation of failures of internally regulated alternators when fitted with crowbar OV protection and a b-lead disconnect contactor.
Click here to explore the question, "How bad can an alkaline battery be?"
Gauging Pitot Heater Performance - A study in fundamental heat physics.
Economics of Weight Reduction a piece which encourages builders to ascertain the REAL value of weight reduction in their project.
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.
Over the years, AeroElectric Connection drawings have depicted a mixture of progressive transfer switches by Honeywell-MicroSwitch and Carling (who makes the S700-Series switches stocked at B&C). Until all the documentation can be updated to resolve the differences between the two brands Click here for a document on switches that describes the different numbering for the progressive transfer switches.
Click here for Bob's Shop Notes on the differences between ANL current limiters and JJS/JJN series fuses.
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 . . .
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.
An illustrated discussion about spike catching diodes and how they work.
Everything you ever wanted to know about RG batteries but were afraid to ask. . .
"FastOn vs. Ring Terminals . . . What's the Difference?"
"Let's Talk Starter Solenoids"(230K Illustrated).
"Light Emitting Diodes" A little theory and practice for using solid state indicator lamps.
"Spikes and Transient Voltage Suppressors" A list server thread (600K Illustrated).
"Switch Ratings - What Does it all Mean?"
"What's all This Battery Isolator Stuff About Anyhow?" Sport Aviation, December 1995, Page 87
"Fuses or Circuit Breakers?" Sport Aviation, March 1993, Page 86.
Anatomy of a Good Solderless Terminal
Recombinant Gas Batteries Everything you wanted to know but were afraid to ask.
"Avionics Master Switches: Really Necessary?"
"Thermocouples - An excerpt from Chapter 14 of The AeroElectric Connection."
What's the AeroElectric-List About Anyway?
What's all This List-Server Stuff Anyhow?
Vacuum Systems vs. All Electric - a thread on systems that suck.
All Electric Panel - a list server thread . . . .
"Batteries, a list server thread."
Fuses & Breakers . . . to fiddle or not to fiddle, that is the question . . . .
EXP-Bus a review of the on-line advertisement.
EXP-Bus Discussions on the Net
B&C Starters; A net thread . . . .
"What's all This Failure Tolerance Stuff Anyhow?"
What's all This DO-160 Stuff Anyhow?" A two-bit 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.
"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.
Drill Size Chart converts number, letter and fractional drills to decimal inches . . .
"Wire Sizing" Sport Aviation, June 1997, Page 56.
Adel Clamps, everything you wanted to know and were afraid to ask . . .
Down-loadable wiring diagrams in AutoCAD: If you're an AutoCAD user with R12 or later, or AutoCAD Lite -AND- you'd like to develope a wirebook for your project that rivals anything sold for a Learjet, you may wish to take advantage of this offer. I've gathered a collection of drawings along with my entire symbols library into a single file which you're welcome to download and use as you see fit. It includes a project-in-process for a Lancair IVP page-per-system wirebook. You are welcome to Click here to download "wirebook.exe", a self-extracting PKzip file.
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.
Dark-n-Stormy-Night Stories Redux Another good example of how many stories intended to educate and illuminate the inner secrets of aircraft operation fall short . . . especially when it comes to understanding 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.
"If you Can't Afford a Nailgun, Will a Hammer Do?" Plugging into the miracle of GPS on a budget . . . Sport Aviation, November 1996, Page 95.
"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?"
What's all This Major vs. Minor Stuff Anyhow?
"No Juice" a short piece on RG batteries which appeared originally in Aviation Consumer, Februrary 1, 1995. and updated 4-15-98.
"In Memory of Robert L. Nuckolls, Jr."
"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 . . . "
"Should the Justice Department Break up Tiger Woods? . ."
"Big Rocks: A study in practical priorities"
"The Art of War" Tom Adkins
