Spark Plug wires way too long

Airhead · #1 10-01-2012, 11:55 AM

My problem was obvious as soon as I began to route the plug wires. I have a newly purchased Vans IO 360 M1B installed on my 7A. The top plug wires are 24" and 19" too long on the left and right sides, (top only) respectively. After rounds of communication with Vans and Lycoming, I have been to told they are spec'd that way to provide for different engine configurations. Really, what configuration is so different from the standard baffling shown in the plans as to require an additional 24 inches of plug wire? Color me very skeptical. Anyway I was told to just "make it work". Sound familiar?

Well, although extremely disappointed after paying close to 30 grand for an engine, I might as well get on to the "making it work" part. I have spent several hours on a method of tying up the excess wire but am not happy with any of my solutions so far. Has anyone who has encountered this problem arrrived at a method you can share?

BTW, has anyone else encountered this problem?

Thanks

Flying Scotsman · #2 10-01-2012, 02:08 PM

Yep. Same problem with the same engine. I ended up with a reasonable, although not totally elegant, routing. I'll take a pic tonight and post it.

Figured I'd live with it until time for overhauling the mags, then I'd have the harnesses made to the correct length. Not worth changing at this point.

Airhead · #3 10-01-2012, 02:17 PM

Thanks Steve, I'd appreciate that. Do you think we're the only ones with this issue or have you heard of others?

mannanj · #4 10-01-2012, 02:34 PM

They're probably all shipped that way. I bought my engine from a production Mooney and the wires were bundled and zip tied behind the rear engine baffle.

I just left them that way till I installed Robert Paisley's EFII dual electronic ignition system.

Flying Scotsman · #5 10-01-2012, 02:49 PM

I, too, think they're all that way, but for the life of me I couldn't figure out *why*. Who on earth would have any sort of baffling/routing that would need wires *that freaking long*?

It was, frankly, a pain in the butt to deal with and made for a less attractive (albeit perfectly functional) installation of the harness.

I'm quite certain that this thread will now start to include all sorts of suggestions about making your own wires, changing to some sort of electronic ignition, etc., etc. LOL!

In the end, it worked out okay, but they'll get changed out at 500 hours.

Airhead · #6 10-02-2012, 09:58 AM

Here is one solution I'm trying on for size. This clearly shows just how much too long these suckers really are. Come on, lets see some photos of these "other configuations" that Vans is refering to that use this wire length.

RV6_flyer · #7 10-02-2012, 11:16 AM

My O320 RV-6 has been flying for 15-years. My spark plug wires run under the oil filter then up to the feed through. Yours is the first one that I have seen that have the wires above the oil filter.

My cowl is off for the installation of a Dynon EMS D10. I will take a photo of my routing on Thursday and post it.

Flying Scotsman · #8 10-02-2012, 12:08 PM

Aw, man...I'm sorry...I totally forgot to take a picture last night for you. Will try to remember this evening, I promise.

Basically, I ran them along the top of the motor mount quite a ways out, doubled them back and then ran them into the cylinders. From there, a little routing with Adel clamps along the pushrod tubes to the plugs.

Will post something tonight, promise.

boomer · #9 10-02-2012, 12:12 PM

[quote=Airhead;703993]My problem was obvious as soon as I began to route the plug wires. I have a newly purchased Vans IO 360 M1B installed on my 7A. The top plug wires are 24" and 19" too long on the left and right sides, (top only) respectively. After rounds of communication with Vans and Lycoming, I have been to told they are spec'd that way to provide for different engine configurations.

When I installed my M1B last year, I noticed the same issue. I called Lycoming Tech Support, and they said not to shorten the wires. They recommended doubling them back and forth at convenient locations (I used the engine mount) and secure with adel clamps. 100 hours later, that solution seems to be working well.

-John

Flying Scotsman · #10 10-02-2012, 12:33 PM

I just wonder why on earth they made them that long in the first place...you could practically run them to another engine on the front of the engine given how long they are!