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Old 12-30-2017, 03:50 PM
9GT's Avatar
9GT 9GT is offline
Join Date: Jan 2010
Location: Southern Michigan
Posts: 2,189
Default Tip: DIY Penetration Kit For Under $10!

I couldn't bear the thought of spending $57 for a 3/4" firewall penetration kit so I did some digging around on the internet. I found these on Amazon in a variety of sizes and quantities. Two for $7.85, and free shipping with my Prime membership: . 2" X 1/2" stainless steel washers from my favorite hardware store at .45 cents each. They work as a backer on the cabin side of the firewall. Just drill out the 1/2" hole to 3/4" with a good Unibit and deburr, then match drill the mounting holes, or drill new ones to suit. I had a foot of 1" I.D. silicone fire-sleeve leftover from another project and have a tube of 3M 200 Fire Stop sealant to seal up the firewall on hand. Add a couple SS worm clamps and your good to go. The flanges have a drilled hole in side of the tube for a set screw but the sealant, worm clamp, and overlaying fire sleeve will take care of that. I have a TIG so will probably weld the holes closed though I do not thing it is necessary. So here I have 2 nice stainless steel firewall penetration kits for about $5.00 each.
[IMG]DSC01987 by David C, on Flickr[/IMG]
[IMG]DSC01988 by David C, on Flickr[/IMG]
David C.
Howell, MI
RV-10: #41686 Under Construction
RV-9A: #90949 Under Construction
RV-10: #40637 Completed/Sold 2016
Cozy MKIV:#656 Completed/Sold 2007
"Donor Exempt" but donated through Dec. 2021

Last edited by 9GT : 12-30-2017 at 03:56 PM.
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Old 12-30-2017, 04:19 PM
Mike S's Avatar
Mike S Mike S is offline
Senior Curmudgeon
Join Date: Sep 2005
Location: Dayton Airpark, NV A34
Posts: 16,100

Ah........the joy of experimental aviation
Mike Starkey
VAF 909

Rv-10, N210LM.

Flying as of 12/4/2010

Phase 1 done, 2/4/2011

Sold after 240+ wonderful hours of flight.

"Flying the airplane is more important than radioing your plight to a person on the ground incapable of understanding or doing anything about it."
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Old 12-30-2017, 06:49 PM
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wirejock wirejock is offline
Join Date: Oct 2005
Location: Estes Park, CO
Posts: 4,770
Default Firewall pass thru

Excellent. Not too far away so I'm ordering a few. Thanks for the tip.
Larry Larson
Estes Park, CO
wirejock at yahoo dot com
Donated 12/01/2021, plus a little extra.
RV-7A #73391, N511RV reserved (3,000+ hours)
Empennage, wings, fuse, finishing kit done. Working FWF
I cannot be, nor will I be, held responsible if you try to do the same things I do and it does not work and/or causes you loss, injury, or even death in the process.
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Old 12-30-2017, 09:17 PM
160kt 160kt is offline
Join Date: Feb 2005
Posts: 89
Default Stainless steel Flange

I’m curious what alloy of Stainless these flanges are made from? Could you put a magnet on one and see if it sticks at all? I like to keep magnetics to a minimum in front of the compass.

Last edited by 160kt : 02-21-2018 at 06:58 PM.
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Old 12-31-2017, 01:37 AM
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rv8ch rv8ch is offline
Join Date: Feb 2005
Location: LSGY
Posts: 4,316
Default Great idea!

I used this method with my first engine, and it was very good. For a flange and tube, I used stainless steel bathroom safety grab bars.

For the second engine, I purchased the well-known kits, since I needed much smaller penetrations.

I've seen many methods on RVs and certified aircraft that I wouldn't feel comfortable with, like just a hole with a dab of RTV to "protect" the wires, plastic snap bushing with RTV, rubber grommet with nothing else, and even the rubber grommet with the stainless steel cover, but these aircraft seem to have been signed off and fly. ?\_(ツ)_/?
Mickey Coggins
"Hello, world!"
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Old 12-31-2017, 09:26 AM
Electrogunner Electrogunner is offline
Join Date: Aug 2016
Location: Quarryville ,pa
Posts: 592
Default FWF

I literallly just installed my stainless steel shower rod holders last week. Glad to see I?m not the only thrifty one in the bunch. I just could not spend $60/ea on them. I did cut mine down to the set screw though.
RV10 N821BS coming soon
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Old 12-31-2017, 06:51 PM
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hgerhardt hgerhardt is offline
Join Date: Oct 2006
Location: torrance, ca
Posts: 745

Another nice way is to take a steel AN bulkhead fitting and bore out the hole on a lathe. You can also turn down the OD and remove the threads everywhere except where the nut needs to go to lighten it.
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Old 01-01-2018, 12:23 PM
Ethanol1 Ethanol1 is offline
Join Date: Oct 2007
Location: MN
Posts: 86
Default No longer available

You must of bought the last ones.
Mike York
President EAA Ch 25
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Old 01-01-2018, 12:49 PM
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kentlik kentlik is offline
Join Date: Sep 2015
Location: Oregon
Posts: 895

Originally Posted by Ethanol1 View Post

Here are similar items.
RV-7A in progress
Private pilot, ASEL!
EAA 105 Chapter 7S3
Bi-annual financial contributor

"The credit belongs to the man who is actually in the arena..." Teddy Roosevelt
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Old 01-01-2018, 12:56 PM
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Av8torTom Av8torTom is offline
Join Date: Nov 2009
Location: Yardley, PA
Posts: 1,361
Default Great idea!

They remind me of SS marine rail fittings. These might be on the heavy side, but offer a choice of angles.

RV-9A (empennage completed, both wings completed, fuselage and finish kit completed, engine hung, working on panel and wiring)
N677AT reserved
Superior XP O-320, 160HP
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