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Got called out for my wire routing on a Cessna 172 annual
My lead at the Phoenix shop saw my work on a nav light circuit and said, 'That's a rat's nest waiting for a chafe point.' He made me redo it with proper clamps every 7 inches and a 3-inch service loop. I used to just zip-tie things to get them out of the way. Now I spend the extra 20 minutes doing it right. Anyone have a favorite clamp or tie method for tight spaces behind a panel?
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stellap496mo ago
a few extra zip ties never hurt anyone" is exactly the kind of thinking that gets mechanics in trouble. Those 40 year old planes you mentioned are flying in spite of the bad work, not because of it. I've cut out dozens of wires that were half worn through from rubbing on a bundle that was just zip tied tight. The rules are written for the one time something goes wrong, not for when everything is fine. Saving 20 minutes now could mean finding a failed system or a fire later.
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brookep626mo ago
My old shop in Tucson never made a big deal about wire routing as long as it was secure. I get the safety idea, but a few extra zip ties never hurt anyone. The 7-inch rule feels like overkill for a simple nav light wire that barely moves. Sometimes the "right" way just adds time and parts cost for a problem that almost never happens. I've seen plenty of 40-year-old planes flying just fine with what you'd call a rat's nest behind the panel.
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