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  #1  
Old 08-28-2012, 02:42 PM
Michael Burbidge Michael Burbidge is offline
 
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Location: Sammamish, WA
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Default Wiring between main and starter contactor...

I'm using a short length of battery type cable made by B&C to connect my main contactor to the starter contactor. Both contactors are from B&C. The orientation of the terminal bolts on the contactors does not make for using copper bar easily.

I've enclosed a picture. My question is, do you the think the radius of the bend will put too much stress on this wire? If so, what would you suggest?

Thanks,
Michael-



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Old 08-28-2012, 06:22 PM
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mannanj mannanj is offline
 
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Default Cable

Looks ok to me from here. If you're worried about it, make a new one with welding cable. It is super flexible and should make that radius easily.
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  #3  
Old 08-28-2012, 07:24 PM
Frank Smidler Frank Smidler is offline
 
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Default Bend it

You can shorten the wire and bend the terminal connection over 90 degrees to make a neater installation. That being said, it looks OK as it is as long as it will not rub against the battery box.
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Old 08-28-2012, 07:59 PM
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Captain_John Captain_John is offline
 
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Default

...or do it like i did with a twist in the copper bar.



. CJ
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Old 08-28-2012, 08:00 PM
TX7A TX7A is offline
 
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Default

You probably knew this, but when you crimp the terminals on, make sure they are "clocked" so you don't have to twist the cable when you put the ends on the studs. Don't want to introduce any stress.
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  #6  
Old 11-11-2012, 07:30 AM
idleup idleup is offline
 
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Default

CJ,

Where did you get that copper bar you used to interconnect the contactors and what size/thickness is it? Also, how did you do the black on there, it looks like rubber. Thanks

Matt

Quote:
Originally Posted by Captain_John View Post
...or do it like i did with a twist in the copper bar.



. CJ
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  #7  
Old 11-11-2012, 07:42 AM
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UnPossible UnPossible is offline
 
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Default

Vans sells copper bus bars. http://vansaircraft.com/cgi-bin/stor...oduct=buss-bar

To me it looks like the black is just heat shrink tubing.

Hope this helps,
Jason
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  #8  
Old 11-11-2012, 07:44 AM
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Mel Mel is offline
 
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Quote:
Originally Posted by idleup View Post
CJ,
Also, how did you do the black on there, it looks like rubber. Thanks
Matt
Looks like heat-shrink tubing to me.

p.s. Obviously Jason types faster than I do. My recent eye surgery has slowed my keyboard!
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Last edited by Mel : 11-11-2012 at 07:46 AM.
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  #9  
Old 11-11-2012, 08:32 AM
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az_gila az_gila is offline
 
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Quote:
Originally Posted by UnPossible View Post
Vans sells copper bus bars. http://vansaircraft.com/cgi-bin/stor...oduct=buss-bar

.......

Hope this helps,
Jason
If you want to equal #2 gauge wire, you should use two strips of Vans bus bar in parallel.

One strip is only about 55% the copper cross-section area of a #2 wire.
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  #10  
Old 11-11-2012, 10:13 AM
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DanH DanH is offline
 
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Default

Quote:
Originally Posted by Michael Burbidge View Post
My question is, do you the think the radius of the bend will put too much stress on this wire?
No. The minimum radius for a wire is roughly the same as the minimum bend radius for sheet or bar material with thickness equal to the individual wire strand diameter. Put another way, the concern is cracking of the individual strands, just like cracking an aluminum sheet part by using a bend radius that is too small.

You're not anywhere near the plastic region for those wire strands.

Concern about "preload stress" is baseless. Consider your torque-to-length Lycoming connecting rod bolts, or the stress on your landing gear right now, sitting quietly in the hangar.
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