Tip: Co-pilot stick wiring

[Mark Burns]

Originally Posted by Bill Wightman

EXCELLENT solution Mark!!! I'm gonna do it, thanks very much!

Your first post here has a pic that's not linking... maybe its the pic of the receiving plug. I'd like to see that.

Thanks Bill.
I got the photo working.

Mark

[Harold Lanfear]

Mark,
Thanks for the idea; I'd been toying with that but not sure how to align the pins and sockets without wear. You've solved that and more.

Can you add some detail how you positioned the plugs while you epoxied them in place? That would be most helpful.

For those wanting a positive way to hold the stick in place, there is enough room alongside the plug to drill and tap a hole for a short screw, just protruding through the stick, but not touching the plug. The outer hole (socket) doesn't need to be tapped. The fairly thin stick will have plenty of threads to hold the screw since the only force will be in shear.

Harold

[Mark Burns]

Originally Posted by Harold Lanfear

Mark,
Thanks for the idea; I'd been toying with that but not sure how to align the pins and sockets without wear. You've solved that and more.

Can you add some detail how you positioned the plugs while you epoxied them in place? That would be most helpful.

snip

Harold

Harold,
I wish I had taken more photos during the fitting.
I installed the connector on the stick side first. I used a mating DB9 with the "ears" still on it to but up against the end of the tube. This positioned the connector inside just flush. I "packed" some foam rubber about 1" from the connector inside the tube through a hole that I had originally made to run the wires out the side. This was to keep the epoxy from running out. You can't see this hole in the photos. I turned it connector up and carefully poured "dobbed" the epoxy down and around the connector.

The next day after the stick connector was in place I placed the connector for the reciever with wiring onto the stick. I used ivory soap as a mold release. Smearing it in the places I didn't want the epoxy to stick. I carefully slid this assembly into position into the reciever and poured about an inch worth of epoxy inside. I had smeared some RTV silicone around the wires where they entered the backside of the connector so the epoxy wouldn't run inside the connector.

I hope this description of the process helps. But I'm sure there are many ways to end up with the same result.

Mark