Wing electrical connector planning

Deutsche DTM, DT and DTP connectors will be used, using nickel plated solid connectors and the HDT-48-00 crimp tool

Centre fuselage to wing connections:

RH wing:

USB camera mount: 2 core 18AWG shielded tefzel MIL-C-27500 18TG2T14 -

1x Deutsche DTM3-2 (purple band terminals)

Nav lights - 4 core shielded 18AWG tefzel MIL-C-27500 18TG4T14

1x Deutsche DTM6-2 (purple band terminals)

Taxi lights - 2 core shielded 16AWG tefzel MIL-C-27500 16TG2T14

1x Deutsche DT3-3 kit with E seals

Landing lights - 2 core shielded 16AWG tefzel MIL-C-27500 16TG2T14

1x Deutsche DT3-3 kit with E seals

LH wing:

Nav lights - 4 core shielded 18AWG tefzel MIL-C-27500 18TG4T14

1x Deutsche DTM6-2 (purple band terminals)

Taxi lights - 2 core shielded 16AWG tefzel MIL-C-27500 16TG2T14

1x Deutsche DT3-3 kit with E seals

Landing lights - 2 core shielded 16AWG tefzel MIL-C-27500 16TG2T14

1x Deutsche DT3-3 kit with E seals

Pitot heat:

Heater 2 x MIL-W-M22759/16-12 12 AWG tefzel

1x Deutsche DTP2-1 kit with E seals

Sense 1 x MIL-W-M22759/16-16 16 AWG tefzel

Use one wire from the DTM6-2 kit

Rear fuselage to Horizontal stabiliser connection:

Trim motor - 5 core shielded 22 AWG tefzel MIL-C-M27500 22TG5T14 in fuselage connected to Olflex classic FD810 P 5G0.5 unshielded multicore cable (20AWG)

1x Deutsche DTM6 kit

Rear fuselage to Vertical stabiliser connection:

Tail strobe - 4 core shielded 18 AWG tefzel MIL-C-M27500 18TG4T14 in fuselage connected to Olflex classic FD810 P 4G0.5 unshielded multicore cable (20AWG)

1x Deutsche DTM4-2



These Olfex multicore cables have 0.5mm^2 conductors, so this is 20AWG. Since these are unshielded the tefzel shield will be terminated and not bought out to one of the connector pins. This Olfex cable has been chosen for its flexibility to repetitive movement, something which I believe tefzel is not well suited for.

2x Deutsche DTM3

For the overhead LEDS

Summary, with component subtotals

4x Deutsche DT3-3 kit (DT3-M from CTALS) - wing taxi and landing lights (16-16AWG)

• 1 x Deutsch DT04-3P-C015 Receptacle with E seals
• 1 x Deutsch DT06-3S-C015 Plug with E seals
• 5 x Deutsch 0462-201-16141 Sockets
• 5 x Deutsch 0460-202-16141 Pins
• 1 x Deutsch W3S Wedge
• 1 x Deutsch W3P Wedge

1x Deutsche DTM3-2 kit (DTM3-PR from CTALS) (purple band terminals) - LH wing usb (18-18AWG)

• 1 x DTM04-3P 3 way plug
• 1 x DTM06-3S 3 way receptacle
• 1 x WM3S Wedge
• 1 x WM3P Wedge
• 3 x 0460-010-20141 purple band Pins
• 3 x 0462-005-20141 purple band Sockets

2x Deutsche DTM6-2 kit (DTM6-PR from CTALS) (purple band terminals) - wing nav lights (18-18AWG)

• 1 x DTM04-6P 6 way plug
• 1 x DTM06-6S 6 way receptacle 
• 1 x WM6S Wedge
• 1 x WM6P Wedge
• 6 x 0460-010-20141 purple band Pins
• 6 x 0462-005-20141 purple band Sockets

1x Deutsche DTM6 kit (DTM6-G from CTALS) - gold contacts - trim motor (22-20AWG)

• 1 x DTM04-6P Receptacle
• 1 x DTM06-6S Plug
• 1 x WM-6P Wedge
• 1 x WM-6S Wedge
• 6 x 0460-202-2031 Gold Pins
• 6 x 0462-201-2031 Gold Sockets

6x Deutsche 2325530-1 sockets (22AWG) to match the 22AWG fuselage cable

Alternatively Need to double over the 22AWG cable to match the sockets (20AWG, just maybe crimpable down to 22AWG)

1x Deutsche DTM4-2 kit (DTM4-PR from CTALS) (purple band terminals) - tail strobe light (18-20AWG)

• 1 x DTM04-4P 4 way plug
• 1 x DTM06-4S 4 way receptacle 
• 1 x WM4S Wedge
• 1 x WM4P Wedge
• 4 x 0460-010-20141 purple band Pins
• 4 x 0462-005-20141 purple band Sockets

4x Deutsche 0460-202-20141 pins (20AWG) to match the 20AWG VS cable

1x Deutsche DTP2-1 kit (DTP2 from CTALS) - pitot heat power (12-12AWG)

• 1 x DTP04-2P-C015 Connector Socket with E-seal
• 1 x DTP06-2S-C015 Connector Plug with E-seal
• 2 x 0462-203-12141 Contacts
• 2 x 0460-204-12141 Contacts
• 1 x WP-2S Wedge
• 1 x WP-2P Wedge

2x Deutsche DTM3 kit (DTM3-G from CTALS) - gold contacts - overhead lights (22-22AWG)

• 1 x DTM04-3P Receptacle
• 1 x DTM06-3S Plug
• 1 x WM-3P Wedge
• 1 x WM-3S Wedge
• 3 x 0460-202-2031 Gold Pins
• 3 x 0462-201-2031 Gold Sockets

6x Deutsche 2325531-1 pins (22AWG) to match the 22AWG fuselage cable - or double over connections

3x Deutsche 2325530-1 sockets (22AWG) to match the 22AWG fuselage cable - or double over connections

Insulation diameter range

See page 118 of

https://www.te.com/content/dam/te-com/custom/documents/ts-ict-t-c-cat-2018/docs/TS-ICT-T-C-CAT-2018.pdf

Contact size 20 - standard 1.35-3.05mm

Contact size 16 - standard 2.23-3.68mm, E seal 1.35-3.05mm

Contact size 12 - standard 3.40-4.32mm, E-seal 2.46-4.01mm

Thick-walled (stand alone wire) MIL-W-22759/16 Tefzel insulation diameter

12 AWG 2.82-2.97mm => use E-seal DTP

16 AWG 1.96-2.06mm => use DTM purple band or E-seal DT

18 AWG 1.75-1.85mm => use DTM purple band or E-seal DT

20 AWG 1.47-1.57mm => DTM

22 AWG 1.27-1.37mm => add heat shrink jacket to wire for use with DTM

Thin-walled (in M27500 cable) MIL-W-22759/18 Tefzel insulation diameter

16 AWG 1.73-1.83mm => use DTM purple band or E-seal DT

18 AWG 1.50-1.60mm => use DTM purple band or E-seal DT

20 AWG 1.24-1.35mm => possibly add heat shrink jacket to wire for use with DTM

22 AWG 1.04-1.14mm => add heat shrink jacket to wire for use with DTM