Fuel Tank Sender Wiring... When and What?

danielhv · #1 03-27-2009, 06:29 AM

I just finished patching a leaking tank... so in a week or so I'll pressure test, and then hopefully install it onto the wing spar for good... (Is there any other reason to remove it?, should I wait before I go torque sealing everything?) My question is what do I do about fuel sender wiring? I'll obviously need to hook it up and have the wire sitting loose somewhere... do you guys just run it along the forward side of the spar between the tank? Or take it down into the wing conduit somewhere? And what kind of wire do I use?

jsharkey · #2 03-27-2009, 07:01 AM

I used 18 gauge wire. Probably over kill.
Ran forward between the wing and fuselage, thus forming a service loop, and through a small rubber grommet just aft of the F-602 sub-bulkhead. Secured to these bulheads and up into the harness bundle behind the panel before reaching the gauges which in my case are on the top RHS of the panel.
Just one option - neat and simple though.
Jim Sharkey
RV6 - getting there!!!!

Mel · #3 03-27-2009, 07:06 AM

Daniel, the fuel gauge draws practically no current so wire size is not important. I never go smaller than 20 ga. just for ease of working. Where you run the wire is your choice. Just don't run it through the same hole as the fuel line. Electrical and fuel lines each need their own hole.

dhall_polo · #4 03-27-2009, 07:09 AM

I did capacitive tanks, but the answer is probably the same. The connector is on the inboard side of the tank, next to the fuse. It's not practical to do the fuel gauge line with the rest of the wing wires. I ran the fuel gauge line into the fuse where the main fuel line enters the fuse. This is something you don't have to worry about till you're done with the fuse and doing all the other wiring.

danielhv · #5 03-27-2009, 08:05 AM

Quote:

Originally Posted by Mel

Daniel, the fuel gauge draws practically no current so wire size is not important. I never go smaller than 20 ga. just for ease of working. Where you run the wire is your choice. Just don't run it through the same hole as the fuel line. Electrical and fuel lines each need their own hole.

So I can use any kind of wire? Size is the only determining factor? I guess what Im asking is: can I go to Lowes and use the 20ga or 18ga wire from there? Or does it need to be some special Aviation grade wire?

Mel · #6 03-27-2009, 08:21 AM

I don't recommend using anything but "aviation wire" in any aircraft. With hardware store wire, you never know what you are getting.

chaskuss · #7 03-27-2009, 08:22 AM

Quote:

Originally Posted by danielhv

So I can use any kind of wire? Size is the only determining factor? I guess what Im asking is: can I go to Lowes and use the 20ga or 18ga wire from there? Or does it need to be some special Aviation grade wire?

Dan,
Aviation wire is what you want. Aviation wire has more strands (increases flexibility), the strands are tinned (coated with solder to prevent corrosion) & the Tefzel insulation is extremely abrasion resistant. Industrial wire has PVC insulation, which will break down over the years. It is nowhere near as abrasion resistant as W22759/16 aviation wire. Aviation wire is finding it's way into automobile manufacture, due to it's high quality. See

http://www.militarywire.org/mil-w-22759.htm

http://www.steinair.com/wire.htm

Charlie Kuss

jsharkey · #8 03-27-2009, 08:22 AM

Quote:

Originally Posted by danielhv

So I can use any kind of wire? Size is the only determining factor? I guess what Im asking is: can I go to Lowes and use the 20ga or 18ga wire from there? Or does it need to be some special Aviation grade wire?

Oh - I'd use aerospace grade Tefzel everywhere!
MIL-W-22759/16 - get if from Stein or Spruce or Van's
Good insulation and light weight - plus fire and wear proof.

SteinAir · #9 03-27-2009, 08:44 AM

Quote:

Originally Posted by danielhv

So I can use any kind of wire?

No.

Quote:

Size is the only determining factor?

No.

Quote:

I guess what Im asking is: can I go to Lowes and use the 20ga or 18ga wire from there?

No.

Quote:

Or does it need to be some special Aviation grade wire?

Yes.

Everyone covered this good in their answers. Just start buying wire now, because from this point forward you'll need a piece here and there for various things. AWG20 will suffice just fine for the fuel senders.

Cheers,
Stein

danielhv · #10 03-27-2009, 10:06 AM

Quote:

Originally Posted by SteinAir

No.

No.

No.

Yes.

Everyone covered this good in their answers. Just start buying wire now, because from this point forward you'll need a piece here and there for various things. AWG20 will suffice just fine for the fuel senders.

Cheers,
Stein

Ok, sorry for the noob questions, the wiring aspect of this is all new to me... So im going to go with the AWG20, white, how much of it should I buy? And what kind of connectors do I need for the float senders?