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The Electrical Blues of Re-wiring

Posted By:
Frank Childers
Homebuilder or Craftsman
#1 Posted: 5/18/2010 00:38:43

Really don't know where to start
confused. Hello aviators, I own or should I say I'm building a Pulsar III aircraft.  There are few of these flying around the globe.  This model was introduced in the late 90's from my understanding.  Not here to give you all a history lesson. 

Actually, I've got a problem that concerns me regarding the re-wiring of my aircraft.  She (my aircraft) is about 85% completed to this point.  Now I'm in the cockpit re-doing my panel.  I didn't like the previous owner's design and now I'm upgrading some of the equipment/instruments, switches, stick grip, etc.  Without going into a lot of detail, I'm not electrical savvy.

I have some questions regarding wiring.. Can anyone point me to a good website, video or book tutorial with lots of pictures and diagrams? I have a Rotax 912S without an alternator so I know I'm working with approximately 18 amps through my rectifier regulator.  How do you determine total load? What's the best approach to using circuit breakers?


Rick Pellicciotti
Young Eagles Pilot or VolunteerHomebuilder or Craftsman
#2 Posted: 5/18/2010 09:05:02

You should start here:


This is the bible on how to wire aircraft.  There are specific sections on composite aircraft and Rotax 912 engines.  Buy Bob's book, study the downloadable material on his web site and you will have just about everything you need to do the job.  Bob also does a forum at Airventure every year.

In the past, I have tried to go behind someone else and fix/modify their wiring.  I have usually found it to be easier to just pull everything out and start over from scratch.

Here is a link to a web page where I recently upgraded a six-pack panel to EFIS in a Long-EZ:


There might be something useful to you there.


Rick Pellicciotti, Falco N63KC http://www.prowlerjaguar.com
Tom Henry
AirVenture Volunteer
#3 Posted: 5/23/2010 16:01:01

The only thing I would add is KEEP IT SIMPLE.

So many people attempt to build in mutiple levels of redundancy (which aeroelectric explains very well how to do) in a simple VFR only aircraft which don't need the weight, complexity or added failure modes.

A simple electrical system like that on a Cherokee 140 provides all the redundancy needed for VFR and even occasional light IFR and is very simple to design (copy it from Pipers maintenance manual), troubleshoot, maintain and install.

Remember the BATTERY is your backup power source. Maintain it properly. Unless doing IFR regularly that is all you really need.

Good Luch with your wiring.