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Whelen 650E and 500 install


KB4

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Huge thanks to MS ers for the help especially StevenL757 who flew in to personally help me.  Didn’t sync but will do at next annual. AC/Nav brackets holes did not line up with existing nut plates so needed a little fab work to complete.   Used existing power and ground from old power supplies which were all removed.  Saved about 6lbs but need a more accurate scale for exact #.  Unbelievable difference in brightness intensity.  

 

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1 hour ago, Niko182 said:

I'm trying to do my conversion this weekend. Can regular connectors from a computer shop be used or do they need to be certified?
Nik

I think the mechanics will chime in shortly but I think they will need to be waterproof (at least that is what Terry and I did).I can't remember if we used knife disconnects or straight butt connectors.

https://www.aircraftspruce.com/catalog/elpages/knifedisc.php

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I bought them off aircraft spruce. The set goes for about 1300 bucks, but its the last time youll need to replace the lights in the aircrafts life time. Also gain about 4 to 8 lbs of useful load, and the amp usage drops from 15 amps to about 2 to 4 amps.

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6 hours ago, Niko182 said:

I'm trying to do my conversion this weekend. Can regular connectors from a computer shop be used or do they need to be certified?
Nik

I used the heat shrink but connectors, simple easy and sanitary. 

Pritch

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7 hours ago, LANCECASPER said:

Does anyone have any thought as to whether these are make an electrical bond that is secure long term. I got some of them and like them.  But they are so easy, I am afraid I am missing something.

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1 minute ago, DonMuncy said:

Does anyone have any thought as to whether these are make an electrical bond that is secure long term. I got some of them and like them.  But they are so easy, I am afraid I am missing something.

Before I ever allowed my elves to use them I tried one out on two pieces of wire about a foot in length each. After an hour i tried to pull apart the wires and was completely satisfied that this solder was a good connection.  I don't have any evidence of this but it seems much more secure long term than any type of crimping connector.

I used a small heat gun.

(https://www.amazon.com/Wagner-0503038-HT400-Heat-650ᵒF/dp/B000X4SMRQ/ref=pd_di_srch_sabr_2/134-5393021-3486424?_encoding=UTF8&pd_rd_i=B000X4SMRQ&pd_rd_r=acf24912-4825-11e9-8448-5f8f8266119a&pd_rd_w=rwGOq&pd_rd_wg=9CO5w&pf_rd_p=9ef90f7a-801a-4369-9d2c-54e19e59e1d6&pf_rd_r=4D6WCWS8QEH7WQ9NSG97&psc=1&refRID=4D6WCWS8QEH7WQ9NSG97)

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Thanks Lancecasper. That is consoling to know. I was worried that the heat necessary to activate them seemed to be much lower that soldering temperature, and would not bond properly. I like that heat gun. It is neater for this job than the large one I used. Everyone should try these connectors.

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9 hours ago, DonMuncy said:

Thanks Lancecasper. That is consoling to know. I was worried that the heat necessary to activate them seemed to be much lower that soldering temperature, and would not bond properly. I like that heat gun. It is neater for this job than the large one I used. Everyone should try these connectors.

Solder sleeves is what Garmin recommends for all their avionics installs...

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9 hours ago, ragedracer1977 said:

Solder sleeves is what Garmin recommends for all their avionics installs...

Also very interesting to know. I may have to get me one of those small heat guns. They should work much better in tighter spots.

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I finished my install today. Took. Me about 7 and a half hours to do the complete setup. That included removing the powersupplies, re creating new connectors, and replacing all 3 strobe lights, and syncing the wing lights. As of now 2 of the 3 lights are synced and im quite ahppy about it. Also gained 4.2lbs of useful load. Ill add pictures tomorrow when its all signed off.

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Sync all 3 it will look very nice. 

Im doing this job in a Twin Comanche. Unbelievably the strobes and the nav are both on a single wire. Somehow the sync function is combined with that as well. The end result is I have to pull 120’ of 20ga wire to both wingtips and the tail. 

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