Thursday, April 24, 2014

More Wire Fishing - Installing WH-00045 Wire Harness

Work was finished up on pulling in all the wires belonging the WH-00046 wire harness and routing the wires to the specified locations. Two short ground wires needed to be added to the seat ribs on either side of the center tunnel. A hole is in the seat ribs already but the primer needed removing in the vicinity of the hole to insure a good ground. The ground wires will attach to an Adel clamp along with other ground wires which will be installed later down the road.

Was trying to think of a good way to remove the primer without scuffing up the ribs more than necessary so came up with a poor man’s piloted bonding brush by using a drill stop collar that had a piece of crocus cloth attached which was trimmed to the width of the collar. The shaft of the drill bit was slipped through the hole for centering and hand spun to remove the primer.  Worked great!
Crocus cloth cut to the width of the drill stop collar made a good poor man’s piloted bonding brush for removing the primer from around a hole to insure a good ground.
The primer is mostly removed from around the hole but still requires a little tweaking on the right side.
Installed ground wire on the Adel clamp mounted onto the seat rib … bolt not tightened yet because another ground wire will attach here later.

Wires from the WH-00046 were fished through the lower wire grommet in the F-1203A bulkhead and routed either through the seat ribs, all the way aft through the center tunnel or up through the wire hole in the center channel.
Fishing WH-00046 wire harness wires aft through the center tunnel.

After routing the wires of the WH-00046 harness to their proper locations, the outside air temperature sensor was installed and its two wires run all the way aft through the center tunnel.

Next the WH-00045 options wire harness installation began. The grommets in the instrument panel base and F-1202F bulkhead that the WH-00045 harness pass through need to be removed and split to allow a connector that is part of the harness to pass. Builders - do yourself a favor and split those two grommets with a razor blade knife and leave them out until the WH-00045 harness is in its final position in those two areas.

Once the WH-00045 is pulled in through the F-1202 bulkhead grommet, the wires in the harness are split ... some of the wires will run  aft through the lower grommet in the F-1203A bulkhead and continue all the way through the center tunnel. The remaining wires are passed through the upper wiring grommet in the F-1203A bulkhead.
Separating and untangling the wires in my left hand that will run through the lower grommet in the F-1203A bulkhead all the way aft through the center tunnel. Wires in my right hand will go through the upper wire grommet in the F-1203A bulkhead.

The WH-00045 harness wires that needed to go all the way aft were fished through the wire grommets in the center channel's bulkheads one at a time.  A long string was run through the center channel bulkhead's wire grommets and taped onto the wire being pulled in through the wire grommets. The string was cut plenty long so it could be looped over the center channel and taped 6" or so further back on the wire being pulled in.  As the wire was being pulled in through the center channel's bulkhead grommets, it was also pulling the pull string back through the grommets so there would be a pull string ready for the next wire to be pulled through the grommets.
Pulling a wire through the center channel’s wire grommets ... the string used for pulling was looped back and taped onto the wire so the string was pulled back through the center channel wire grommets as the wire was being pulled through the center channel's bulkheads.