Passing wires through the baffles

[Bryan Cotton]

When I wired up my aircraft, several wires were passed through small holes/grommets and then terminated. Very neat, until you have to pull the engine or baffle and have the soul-crushing realization that you need to unterminate all the wires and then do it over. So when I was pulling my engine the last time, for the sake of reshimming the engine up & replacing the rear main seal, I went a little nuts and cut some passages to the breather hole. This allowed me to snake the wires over to that hole and then pull them out. I didn't have to remove my type K connectors or anything. It was great, but then I had to figure out how to put it back together. Here is my solution.

baffle penetration thing apart.png (603.29 KiB) Viewed 1851 times

I have not decided if the clecoes will become nutplates, screws and nuts, or if I will just use aluminum pops and drill them out when required.

baffle penetration thing clecoed.png (557.5 KiB) Viewed 1851 times

If you have not done your baffles yet, you may want to consider something similar. It would actually be much easier if you drilled the holes in the baffle and the cover plate at the same time, rather than try and match them up after.

Also for some of my wires I had to cut the grommet to put it back in. With this setup that would not have been required.

[Bryan Cotton]

I've decided on aluminum rivets when it's time to reinstall. Trial fit:

front side baffle penetration.png (690.79 KiB) Viewed 1803 times

The other side:

back side baffle penetration.png (718.47 KiB) Viewed 1803 times

One of my buddies sent me his solution:

Rob's baffle penetration.png (315.92 KiB) Viewed 1803 times

[Bryan Cotton]

Finished:

Screenshot_20240220-093118-679.png (733.18 KiB) Viewed 1396 times

[Weatherpilot]

Nice Bryan.