Finished avionics wiring harness: 6 hours

• The avionics wiring harness (except for engine sensors) is complete! I will be installing it soon.
• Finished GTN 650 data wiring.
• For power wiring on GTN 650, which requires splicing a larger wire into two or three wires multiple times, I decided to use the solder splices. They worked great. Next time around I will use them more often - much easier than the soldering iron!
• Connected GTN 650 configuration module and fan connector wiring
• Assembled all GTN 650 backshells
• Organized wire harness
• Added power and ground wires to GMA 245R audio panel connector and GTX 23R transponder connector

GTX 23R connector ready for  back shell:

Avionics wiring harness ready to be installed:

A lot of shield drains on the main GTN 650 connector:

GTN 650 backshell (note config module on left and fan connector):

Solder splices work great!

Old school solder splicing:

GEA 24 and other connector work: 3 hours

• I could not resist powering up the GDU 460. The screen looks great!
• Finished all CAN bus wiring except for the two connections that have to be made with the wiring harness in place. I will use solder splices instead of soldering for those two.
• Finished the GEA 24 (engine data) power connector other than the CAN bus pins.
• Made progress on connecting the GTN 650 gps / nav / com to the audio panel.

GDU 460 power test!:

CAN bus prep:

GEA 24 power / CAN bus connector:

GTN 650 and GMA 245 connector work:

GSU 25 Connectors: 2 hours

I got the connectors for the GSU 25 ADAHRS done except for the CAN bus which will have to be done in place. This is because the ADAHRS CAN bus connects to the wiring for the autopilot servos which is already in.

The CAN bus is a reliable daisy chain network that connects most of the avionics. However it could be a single point of failure so Garmin has a back up data line between an ADAHRS and a flight display. I wired this between the #1 ADAHRS and the main PFD.  Now if the primay network fails I will still have all the information I need to control the airplane in bad weather.

I also decided I would put in the second VFR GPS antenna under the cowl and connect it to the MFD. It weighs very little and gives a bit more redundancy. Also both flight displays can share the good GPS data if one antenna is having a problem.

Two VFR GPS antennae:

GSU 25 wiring complete aside from CAN bus:

Back up RS-232 connection between ADAHRS 1 and the main flight display:

Wire harness progress: 9 hours

The following work was done over two days:

• Assembled connectors for GAD 29. The GAD 29 allows the GTN 650 navigator to share data with the G3X system.
• Started wiring the two main GTN 650 connectors
• Started wiring the two GMA 245R audio panel connectors - all of the audio panel and GTN navigator connectors use high density pins which are smaller and more of a hassle to work with.
• Modified the CAN bus plan so I can assemble the GTN 650 connector on the bench. I have 3 devices that will to have their connectors assembled in the aircraft due to the layout of the CAN bus.
• Connected the configuration module for the GDU 460 primary flight display. This is essentially a memory chip that is mounted inside the connector and stores all system setup data so that if you have to swap a unit out for maintenance you won't loose your aircrafts specific setup data.
• Finished the main GDU 460 connector

Avionics wire harness so far:

GDU 460 connector (configuration module is barely visible under the right wire bundle):

Configuration module and connector (very small wire = hard to work with):

Starting GTN 650 connectors:

Finished GAD 29 - GTN 650 interface connector:

Modified CAN bus layout:

Audio panel connectors in progress:

GAD 29 power and CAN bus connector:

Finished GDU 450 connector: 2 hours

Finished the GDU 450 connector:

• Added primary and secondary power wires
• Added a ground and soldered a splice for primary and secondary pins
• Soldered / assembled my first CAN bus node
• Assembled back shell and shield drains

GDU 450 connector with GDL 39R connector on left:

Prior to adding back shell:

CAN bus node:

Started building the G3X wire harness: 3 hours

• Assembled the wires and connector for the GDL 39R ADSB receiver. This connects to the GDU 450 which will be set up as the multi function display (MFD).
• Ran the antenna cable for the vfr gps antenna for the G3X display units. All gps antennae will be mounted under the engine cowling just forward of the firewall.
• Installed the fire sleeve on the other two firewall wiring pass through's

Harness for GDL 39R connecting to GDU 450 multi function display (MFD):

Fire proof wiring pass through's with VFR gps antenna:

Still more wiring: 3 hours

• Spent some time cleaning up and organizing the wires in the tunnel
• Added pins and solder sleeves to all headset wires
• Finished a connector for #2 ADAHRS - probably the easiest - one wire between two pins in the connector
• Cleaned up and organized for putting together the G3X wire harness
• Put the panel, G3X GDU 460 & 450, and GTN 650 tray in place
• Measured wire lengths for most connections and laid them out on the bench for reference when building the harness

Ready to start putting the harness together:

If only all connectors were this easy:

Headset wires ready for connectors:

Tunnel wires looking better:

Fuel pump and TOGA wiring: 6 hours

• Test fitted fuel pump and fuel lines with wiring - no problems with clearance.
• Added a molex connector to fuel pump and ran wire from fuel pump switch and ground block to pump.
• All wiring in the tunnel area should now be complete so I started cleaning up and organizing the wire there.
• Soldered together the recommended two diodes to split the take off go around (TOGA) wire from the stick grip into two wires to go to the G3X (GEA24) and the GTN-650.
• Finished my first connector for the GTN-650! It's the one with only one wire .... TOGA
• Connected headset power wires to VPX
• Organized headset mic and phone wires for audio panel
• Planned next steps for building avionics wiring harness on bench

First GTN-650 connector ... also the easiest! (diodes in black shrink tube on right)

Fuel pump test fit with all tunnel wiring complete:

Fuel pump with snake skin and molex:

Stick grip wiring: 4 hours

I spent a fair amount of time researching and planning the best way to do the stick grip wiring with the main questions being: wiring the push to talk to the audio panel and wiring the a button for go around mode to the G3X and the GTN 650.

The push to talk turned out easy with just needing to connect to an appropriate pin on the audio panel. The go around button will need a little more work requiring two small diodes to isolate the G3X and GTN 650.

The Tosten sticks have 8 switch functions. Here is my set up: trim left, right, up, down, push to talk, auto pilot (cws, disconnect and on depending on how long you the button), take off / go around and as an experiment I will be using one button to play / pause the music going through the audio panel! (I just found this option today.)

Some more details:

• Drilled 3 new wire pass through holes in the sub panel. I was very careful to cover and tape the electronics to keep metal shavings out.
• Added terminals to two pieces of 5 conductor wire for the stick wiring to the panel area.
• Ran the stick wiring forward and then temporarily attached the terminals to the switch wiring terminal block
• Connected the trim switch wires to the VPX and attached pins to the wires going to the audio panel.

Pins ready for the audio panel:

Started the switch input connector on the VPX:

Stick grip button terminal block:

Finished wiring for heated seats: 8 hours

• My seats from Classic Aero Designs include heating elements for the back and bottom. I committed to putting the seat heater switches on the panel early. This made the wiring a little more tricky due to the design of the seat heaters which are made for automotive after market. I spent a fair amount of time figuring out the best way to route the wires and locate the relays.
• I ended up replacing all the connectors with micro molex and almost all the wire with mil spec tefzel.
• The way the system is laid out requires quite a bit of wire. I ran four 18 gauge wires for each seat. 
• I ended up locating the relays for the heaters on the fuselage floor ribs. (The relays allow for two temperature settings.)
• The seat heaters will be a nice feature when the temps drop.
  

Changing out the connectors on a seat back:

Seat heater connectors and relay:

Right seat heater panel switch connector:

Finished one ADAHRS connector plus more wiring!: 6 hours

• Ran the wire for the GMU 22 magnetometer which will mount in the right wing tip. This wire will remain coiled in the wing root until the wing is on.
• Connected the GMU 22 wires to the #1 ADAHRS data connector. This connector also provides power for the GMU 22.
• I did some research and then ran 3 conductor shielded wire for the outside air temp probe which will go under the left wing
• Ran the left and right fuel tank quantity wires
• Connected the outside air temp wires to the ADAHRS.
• Ran the RS-232 wires from the ADAHRS to the GTX 23 transponder
• Assembled the backshell for the ADAHRS connector and connected it!

The completed ADAHRS 1 data connector - 11 pins used plus 4 shield drains:

Adding wires to the connector:

Autopilot servo and electric trim wiring: 3.5 hours

• Ran the wires for the pitch servo forward and connected to the VPX. 
• Connected power wires to the roll trim servo from the autopilot roll servo. (This allows the servo to run the roll trim when required for auto trim.)
• Connected the roll trim servo position wires and ran them forward to the vpx. The roll trim servo uses very small gauge wires so I connected everything with high density dsub pins and heat shrink tubing.
• The wiring for the auto pilot servos and the electric trim servos is pretty much done. The CAN bus network wires still need to be connected to the G3X components. The roll servo wiring is bundled on the outside of the fuselage.
• Drilled a few more wire pass through holes in the fuselage floor ribs. I don't think any more will be required.
• General clean up and vacuum of the fuselage

More wiring and some new pass throughs:

All autopilot servo and trim servo power and position wires (trim servos only):

Roll trim servo connection:

Wiring progress: 8 hours

The following was done over two days:

• After some reserach I soldered the connector for the ELT panel remote and ran shielded wire for ELT to wing root. Also used E6000 (shoe goo) to help strengthen the connection.
• I received another small order from Stein Air so I was able to install the locking switches for the engines computers and ignition coils.
• I also received more connectors so I finished the wiring for the defog fans and the starter arm and push to start switch.
• Tested starter circuit - works great. I also added E6000 to the soldered starter switches to guard against vibration.
• Used E6000 to glue rubber channel to bottom of instrument panel edges
• Researched and corrected wiring for autopilot roll servo. The original wiring was for a the Garmin 305 autopilot control panel. Since I decided to just go with touch screen controls the wiring needed to be changed. It is actually much cleaner now.
• I decided to run the roll servo wiring from the panel out to the wing so I don't have to put a connector at the wing root and I can test the system / servo before the wing is mounted.

Autopilot roll servo wiring:

Connected pitch trim position wires, almost ready to connect autopilot servo wires:

Starter arm and push to start circuit tested:

Soldering ELT panel remote connector: