Planning of midsection interconnect

All the cables running from the centre and rear fuselage have been sized to be able to run all the way to the panel, mainly the circuit breakers and the Dynon avionics. Originally, I planned to have no bulk interconnects which would happen to make the panel not easily removeable. I have reconsidered this position and will fall in line with the standard practise of having such a midsection connection. If done properly it will be possible to remove the panel completely from the aircraft with a substantial proportion of the avionics. This interconnect will involve a mixture of Deutsche (both DT and DTM) and TE CPC Series 2 or DB Connectors, as well as making use of the Dynon network hub.

Dynon network hub

A Dynon network hub will be placed at the midsection interconnects, into which the following units will be plugged

Pitch servo - 4 x 20AWG (network hub via DB9)

Roll servo - 4 x 20AWG (network hub via DB9)

The power and disconnect wires of the two servos will be consolidated into 2 x 20AWG (pos, neg) + 1 x 22AWG (disconnect) and passed through the CPC interconnect defined below

Magnetometer - 9 x 22AWG (network hub via DB9)

Deutsche connector 1 - landing and taxi lights size connector - DT size 16 standard contacts (for 16AWG)

Left landing light - 3 x 16AWG downstream

Right landing light - 3 x 16 AWG downstream

These 6 wires will be consolidated into 4 x 16 AWG (RH pos, LH pos, neg, shld - to provide for wig-wag) and passed to the interconnect

Left taxi light - 3 x 16AWG

Right taxi light - 3 x 16AWG

These will be consolidated into 3 x 16 AWG (pos, neg, shld) and passed to the interconnect

The above groups will be passed through an 8-way panel mount DT connector.

• 1 x DT06-08SA-C015 8-way housing for male terminals with E seals
• 1 x DT04-08PA-CL03 8-way panel mount housing for female terminals with E seals
• 8 x 0462-201-16141 Sockets
• 8 x 0460-202-16141 Pins
• 1 x W8S Wedge
• 1 x W8​P Wedge

Deutsche connector 2 - headset and mic connector - DTM size 20 standard contacts (for 20, 22AWG)

Intercom - pilot mic (3 wires + GND), co-pilot mic (3 wires + GND), pilot phones (3 wires + GND), co-pilot phones (3 wires + GND)

• 1 x DTM06-12SA 12-way housing for male terminals
• 1 x DTM04-12PA-L012 12-way panel mount housing for female terminals
• 12 x 0462-201-20141 Sockets
• 12 x 0460-202-20141 Pins
• 1 x WM12S Wedge
• 1 x WM12P Wedge

... or a kit that combines all these

Deutsche connector 3 - general connector - DTM size 20 standard (for 20, 22AWG) and purple-band contacts (for 18, 16AWG)

Overhead USB - 3 x 18AWG (pos, neg, shld)

RH wing USB camera - 3 x 18AWG (pos, neg, shld)

Rear fuselage USB camera - 3 x 18AWG (pos, neg, shld)

These will be consolidated into 3 x 18AWG (pos, neg, shld) and passed to the interconnect

Left nav/strobe - 5 x 18AWG (neg, pos nav, pos strobe, sync, shield)

Right nav/strobe - 5 x 18AWG (neg, pos nav, pos strobe, sync, shield)

Tail nav/strobe - 5 x 18AWG (neg, pos nav, pos strobe, sync, shield)

These will be consolidated into 4 x 18AWG (neg, pos nav, pos strobe, shield) and passed to the interconnect. The sync lines will be joined but not passed to the interconnect

Pitot heat detect signal (20 AWG)

LH fuel sender - 2 x 20AWG (active, gnd)

RH fuel sender - 2 x 20AWG (active, gnd)

The two grounds will be consolidated, so 3 connections in all

Flap motor - 3 x 22AWG (3 wires+shield)

Flap power wires - 2 x 20AWG (pos, neg)

Flap potentiometer 4 x 22(or 20) AWG shielded tefzel (top, wiper, bottom, shield)

ADSB In - 4 x 22 AWG (pos, neg, serial rx, serial tx)

GPS2020 - 4 x 22 AWG (pos, neg, serial rx, serial tx)

ELT - 5 x 20AWG (4 wires + shield)

Overhead lighting - 3 x 22AWG (pos red, pos white, gnd)

Trim actuator - 6 x 22AWG (5 wires + shield)

Pitch and roll servos - 2 x 20 AWG (pos, gnd) + 1 x 22AWG (disconnect)

LH joystick - trim up, trim down, gnd, ptt, ap disconnect, spare - 6 x 24AWG

RH joystick - trim up, trim down, gnd, ptt, ap disconnect, spare - 6 x 24AWG

LH and RH joysticks lines gnd, disconnect consolidated - so (LH trim up, LH trim down, LH ptt, LH spare, RH trim up, RH trim down, RH ptt, RH spare, gnd, disconnect - 10 lines in all

Total interconnect wires: 3 (usb) + 4 (nav, strobes) + 1 (pitot heat detect ) + 3 (senders) + 2 (flap power) + 4 (flap pot) + 4 (ADSB In) + 4 (GPS2020) + 5 (ELT) + 3 (lighting) + 6 (trim) + 3 (servos) + 10 (joysticks) = 52 wires

HDP20 kit

• 1 x DTM06-12SA 12-way housing for male terminals
• 1 x DTM04-12PA-L012 12-way panel mount housing for female terminals
• ? x 0462-005-20141 purple band Sockets (for 18AWG)
• ? x 0460-010-20141 purple band Pins (for 18AWG)
• ? x 0462-201-20141 Sockets (for 20, 22AWG)
• ? x 0460-202-20141 Pins (for 20, 22AWG)
• 1 x WM12S Wedge
• 1 x WM12P Wedge

... or a kit that combines all these

Alternative multipole connector:

The following TC CPC Series 2 componentry is relevant

Standard

• TE 205840-3 size 17, 28-way square flange receptacle - pins
• TE 205843-1 size 23, 63-way square flange receptacle - pins
• TE 205839-3 size 17, 28-way square flange plug - sockets
• TE 205842-1 size 23, 63-way square flange plug - sockets

Reverse sex

• TE 206038-1 size 17, 28-way square flange receptacle - sockets
• TE 206438-1 size 23, 57-way square flange receptacle - sockets
• TE 206039-1 size 17, 28-way square flange plug - pins
• TE 206437-1 size 23, 57-way square flange plug - pins

The "reverse sex" connectors (the panel mounted connectors are sockets) would match the arrangement of the panel mount DT and DTM connectors

10-100s of the following are needed

• TE 205089-1 size 20 DM pins
• TE 205090-1 size 20 DM sockets

Straight through connections - these are not included in the interconnect

COM cable - RG400U

Sumitomo H-CR-436-36 (20-24AWG - red), H-CR-436-37 (16-20AWG - blue), and H-CR-436-38 (12-16AWG - yellow) will be used for consolidations. These are equivalent to the Raychem D436/36-38 series.

Two wires going into one end of these connectors should be treated as a single wire 2 AWG steps lower