With the tips fitted to the wings, it’s time to run some wiring and finish up the wings. I integrated the Archer nav antenna into the tip mounting hinge which thus links the antenna to the wing for a proper ground plane, per the plans. I used a few pop rivets through the bottom of the tip to secure the antenna in place. I wanted to make the tips easy to remove, so I used bulkhead BNC fittings for the coax on both end of the wings.
I also ran the wires from the trailing edge position / strobe light up towards the main lighting modules and installed a micro fit connector so that the lighting module can be removed for future maintenance / replacement should the need arise. Again, all of the wiring has been documented in Visio including pin outs on each connector so I’ll be able to reference it long after I’ve forgotten how or why I did it this way!
I used CPCs for the main wiring runs and am very pleased with the setup. Some folks avoid connectors like the plague, but I don’t see them as failure points if they are done right and properly tested / treated. I checked continuity of each wire after running them all so I know everything is ready for plug and play. The wing root connectors include those for the pitot heat and AP servo on their respective wings. The aileron trim servo is on it’s own micro fit connector due to the small wire size. I’ve gotten really proficient at the micro Molex connectors and really like them.
I also had to layup a small rib on the trailing edge to not only support the shape of the tip, but also provide a mounting surface for the hinge pin retainer. I used a trimmed block of delrin and nutplate to secure the pins. This keeps the pins inside the tip profile and thus unable to work themselves loose. They also butt up against a stop on the leading edge. I didn’t want to put a bend in them, as it’s very easy to use a drill and spin them in / out.
The only system component not installed in the wing is the OAT sensor which I’ll get with the avionics in a few months. That’ll be simple to put into an access plate and a string is still waiting to pull wires through the wing root.
Since the wings are all complete, I need to get them out of the garage to make way for the finish kit and make me feel like I have real airplane parts in a hangar. My Diamond bros graciously offered a corner of their hangar for me to store the wings in until our hangar is available. So moving day came and anticlimactically went! It was like I designed the wing rack for the trailer and with Ron’s help, they rolled right on and off. We used a few tie downs and took our time on the 10 minute drive to the airport with no damage reported. I hope the fuselage move goes this smoothly!
Bonnie the Bonanza is now babysitting RV wings. Meanwhile, back home the shop has so much room for activities such as finishing the cabin top and getting ready for the finish kit and cowling which are due to arrive early August.
