Electrical connectors - an accident waiting...

[Bruce Hughes]

Longeze has not flown yet so it has not had vibrations at 2400 rpm
all over.

Finally got ready to pump gas to the engine.   Switches UP.....
But was not trying to start - just pump gas.

Nothing happened.   No noise.   No gas flow.   Nada.

Switches off.   Voltmeter out.   Started checking.   Battery OK,
Master switch OK,   Essential circuits OK,   Fuse OK,

Got back to the fuel pump.   Well the warranty is 1 year.......

I have 2 "flat blade connectors" 3 inches from the fuel pump so I
can replace the fuel pump when it goes.   You know - the little steel
connectors that are sold at all auto supply stores.   They are
OK, I guess, for autos but they are junk for airplanes.   The
12 VDC was arriving in the flat blade but the female connector
(clinging so tightly to the male) - had no voltage.   There was
enough corrosion between the 2 that the second was insulated
from the first.

I was surprised when I tried to pull the male and female apart;
the fuel pump started.    

Where do we buy better connectors?

[D]

Yikes!  Glad you found it on the ground, Bruce!!    

I've had great luck with the PIDG blade connectors from Digikey, Allied Electronics, Mouser, SteinAir, Waytek, or any of the aircraft houses (for a modest markup).  Much better than the auto/stereo store variety... and when coupled with a decent crimp tool you'll get a good, gas-tight connection with extra strain relief.

The PIDG variety costs a little extra but they're well worth the peace of mind.  I've even added a length of heat shrink tubing over a few connections just to be double-damn sure.    :wink:

D

[JonC]

Might I suggest....

http://www.aircraftspruce.com/catalog/elpages/knifedisc.php

Use those, slide a plastic tube onto one side, connect them, slide it over the connectors then put a ziptie in the middle. The ziptie will prevent the connector from coming apart, the plastic will prevent arcing and the connectors themselves connect tighter if they are ever pulled on.

These are very common place in certified aircraft.[/url]

[Bruce Hughes]

Hi.   I called all of the businesses that D listed and ordered a
supply of 3 different types (male, female, and ring) from Waytek.  
I was impressed by the on line catalog and the help from an
employee on the phone.   They have minimum order rules but
they gave me a good deal on that.

The connectors are copper with tin plating.   This type will be highly
resistant to corrosion, I think.   I know that tin is used in distilled
water plumbing in preference to stainless steel.

They also carry a high temp. type which is steel with nickel plating.
I don't think I need those.

One of the businesses carried aluminum which I do not trust because
the corrosion that I have seen on aluminum parts in the Longeze.

Digikey was, by far, the most expensive because you have to order
a pkg of 1000.

I WILL have an excellent system when I am done.