Poor mic connection

[0TreeLemur]

The pilot's side mic jac has the PTT switch plugged in.  When my left leg bumps up against the cable which is frequently- especially when maneuvering to land, I get an intermittent mic connection and crackling in the headset.   Pulled the jack out from behind the panel this afternoon to inspect.  It is simple.   Not much to go wrong mechanically.   I unscrewed the backing off the PTT insertion plug and it to is mechanically very simple and well built.   It seems that the problem is just electrical connection.

The PTT insertion plug was once probably shiny brass.  Now it is well oxidized and darkened.   The mic jack contacts are similarly tired.    Any suggestions on a great way to clean both of these up?

Thx.

[LANCECASPER]

Steel wool?

[81X]

Deoxit might be worth a shot. 

[HRM]

Alcohol and Q-tips.

[FoxMike]

Could be in bumping the mic jack you have slightly bent the connector.  Try the cleaning others have suggested and if it does not work replace the connector.  You might look into rudder pedal extensions to move you back a little to prevent  your hitting the jack.

[N201MKTurbo]

Scotch brite 

[carusoam]

4 votes for cleaning...

one vote for how to stop bumping into it...

keep the ideas coming!  

Best regards,

-a-

[RLCarter]

The copper is easily cleaned with a pencil eraser, also check for cold solder joints (loose wire connections)

[0TreeLemur]

The mechanical stuff seems like a short term solution to a long term problem. 

What about a little acid bath then electroplating in something that is highly inoxidible?  Any plating specialists out there? 

Regarding my seat position- I don't bump the actual connector, I move the leads that split and go to the mic and the PTT switch.  They just kind of dangle there from the connector, which protrudes from the panel about3 inches.  I'm 6' tall and ain't gonna use no rudder extensions.

 

[N201MKTurbo]

11 minutes ago, Fred_2O said:

The mechanical stuff seems like a short term solution to a long term problem. 

What about a little acid bath then electroplating in something that is highly inoxidible?  Any plating specialists out there? 

Regarding my seat position- I don't bump the actual connector, I move the leads that split and go to the mic and the PTT switch.  They just kind of dangle there from the connector, which protrudes from the panel about3 inches.  I'm 6' tall and ain't gonna use no rudder extensions.

 

Those plugs are made out of the materials they are made of for good reason. Don’t change it. 

Edited September 23, 2018 by N201MKTurbo

[0TreeLemur]

13 hours ago, LANCECASPER said:

Steel wool?

According to the mfgr, @LANCECASPER is the winner.   See attached image.   I thought about gold plating the plug and jack but that looks expensive.  I'll try steel wool!

[RLCarter]

3 hours ago, Fred_2O said:

I'm 6' tall and ain't gonna use no rudder extensions.

The extensions are not just for the vertically challenged, at 6'1" I have no problem reaching the pedals, but being back another 1.5" or 3.0" gets you away from the panel and gives you more room. The problem on the short bodied Mooney's that extra room is taken away from the back seaters which is limited to begin with. 

[0TreeLemur]

@RLCarter I see.  When in cruise I'll slide back to the first notch back from the takeoff position and stretch out a bit.  I'll ponder.  Thanks.

[0TreeLemur]

Here's what I tried today: BRASSO metal polish.   The oxidized brass connector was quite dark.   Brasso worked great!  Very gentle too- I was afraid that the steel wool might score the surface too much.  The metal polish contains micro-abrasives that worked with very little mechanical effort.   Applied with a micro-fiber cloth, polished for maybe 20-30 seconds, then wiped off.   Plugged everything back in, turned on the avionics, and no more scratchy connection.  Should work for quite a while by appearance.

[0TreeLemur]

Wife's quote after this:  If only everything was so easy.