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Build planning: best route for GPU/trickle charger

R

RNB

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There was some recent discussion about rear bulkheads and different methods of creating a pass through hole for things like wires for trickle chargers and ground power units. My understanding is that the best thing for the structural integrity of the plane is to not weaken the rear bulkhead with holes of any kind, and if any holes are made they might need proper doublers, engineering of which I am not qualified to determine.

I thought that maybe a better solution would be to route the wires under the baggage area floor, bring them up through one of those aftermarket storage boxes. https://fairings-etc.com/products/r...FzdjyDfBk_DTex2d1F6jUhM6SGLLsBKFPAy-69zkflrdn
But I worry that routing things under the floor could interfere with the action of the rudder cables.

For building an RV10, what might be the best possible solution for adding an accessible GPU/trickle charger route? How would you handle this in a new build?
 
RNB said:
There was some recent discussion about rear bulkheads and different methods of creating a pass through hole for things like wires for trickle chargers and ground power units. My understanding is that the best thing for the structural integrity of the plane is to not weaken the rear bulkhead with holes of any kind, and if any holes are made they might need proper doublers, engineering of which I am not qualified to determine.

I thought that maybe a better solution would be to route the wires under the baggage area floor, bring them up through one of those aftermarket storage boxes. https://fairings-etc.com/products/r...FzdjyDfBk_DTex2d1F6jUhM6SGLLsBKFPAy-69zkflrdn
But I worry that routing things under the floor could interfere with the action of the rudder cables.

For building an RV10, what might be the best possible solution for adding an accessible GPU/trickle charger route? How would you handle this in a new build?
Click to expand...
A small hole with round corners in one of the "flats" in the aft bulkhead isn't going to be a problem. I'd find a receptacle (with a cover) that you could mount in that location.
 
The other thing to consider is if you put that connector anywhere in the baggage area, you will need to keep the baggage door cracked to pass the wires while charging.

It isn’t a big deal but something to consider.
 
I have two EarthX batteries and installed powerwerx bulkhead SAE passthroughs, each with a 1 inch hole on a flat of the bulkhead door. I have an extension cord that I gently wedge between the baggage door and fuselage, and plug into a couple of Optimate chargers that sit in the baggage area. It’s been working fine!
 
I have the optimate charging connector accessible through the oil door. no need for more holes. In winter I plug in the tanis heater through the oil door as well.
 
Roo747 said:
I have the optimate charging connector accessible through the oil door. no need for more holes. In winter I plug in the tanis heater through the oil door as well.
Click to expand...
What is the optimate charging connector? Does this function as a GPU and/or charger? What gauge wire and where did you run it?
 
I don't think you need to be afraid of doing anything to that cargo bulkhead, as has been mentioned plenty of people put holes, hatches, etc, in that for various reasons. I put two charging plugs (one per battery) and mounted them behind the cargo corrugated metal. I just cut two 1" holes through the corrugated panel that line up with those. Small round holes have very little impact on strength (hence why they use them everywhere to make parts lighter).

Now if you want to cut something large and/or with different shapes, then all you need to do is build up the area around it. I'm sure somebody can send you to the official specs on exactly what to do, but what I would do is cut another piece of aluminum a few inches larger in each direction and then cleco it in place on the bulkhead. Then cut through both pieces at once, take everything apart and deburr, and then rivet that doubler in place.
 
The connector is just ring terminals for the battery with a male/female plug.
optimate1.com

O-01 Battery Lead |Rings M6-M8 > SAE | 7A max - OptiMate

The OptiMate CABLE O-01 is a SAE battery connector to create an 'easy acces' permanent connection to the battery of your vehicle. Read more!
optimate1.com optimate1.com

Looks like that. I use it for charging and if I need to run the system for maintenance. Works as GPU
 
RNB said:
In your panel or on the rear fuselage? Does it work with multiple gauge wires ?
Click to expand...

I put two of them in my baggage bulkhead. They are used to charge the batteries or provide avionics ground power using my optimate chargers.

As I am flying an electrically dependent aircraft, a gpu start will likely never happen. If there is a problem with a battery it will be fixed.

I used the charge extension cords from earthx though it is an EC5 standard connector. You could make a custom cable using wire size up to the maximum for an EC5 connector.
 
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