Forum: Technology

http://www.youtube.com/watch?v=j5WPw8BqBKA

New splice which can be applied without the use of a heating tool.

PDF Slideshow: http://www.heilind.com/marketing/docume ... d_Pres.pdf

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The only thing I'm seeing as 'NEW' is the gel that environmentally seals the splice. Otherwise this is just another crimp splice. As far as A/C wiring goes, the majority of problems I had were with the wiring itself. I'm sure a majority of the old Kapton wiring has been replace but that stuff was crap. I mean it was a good percentage lighter than standard shielded wires with a plastic insulation but would short to the shield after time.
Regarding the splice, its all about the proper crimp. If a technician decides to wing it, he could either not crimp it enough leading to the wire pulling out, or crimp it too much which would cut the wire off. Crimp tool settings are designed for a reason.
The ability to use a splice without a heat gun prevents damage to the splice and wires from overheating or damage to surrounding wires. Plus its a pain in the butt some times to get a power source out to the flightline.

Sorry double post

Quote:

The only thing I'm seeing as 'NEW' is the gel that environmentally seals the splice. Otherwise this is just another crimp splice. As far as A/C wiring goes, the majority of problems I had were with the wiring itself. I'm sure a majority of the old Kapton wiring has been replace but that stuff was crap. I mean it was a good percentage lighter than standard shielded wires with a plastic insulation but would short to the shield after time.
Regarding the splice, its all about the proper crimp. If a technician decides to wing it, he could either not crimp it enough leading to the wire pulling out, or crimp it too much which would cut the wire off. Crimp tool settings are designed for a reason.
The ability to use a splice without a heat gun prevents damage to the splice and wires from overheating or damage to surrounding wires. Plus its a pain in the butt some times to get a power source out to the flightline.

Nope. Look again. You're using a different crimping tool than the M22520/37-01 red-handled hard splice crimpers. The tool is the M22520/44-01 and crimps onto the splice while it's in the sleeving, much like many splices that are used in the automotive world. SAE and MIL-SPECs have been updated this year for the new Cold Applied Splice. It is actually a bit different than using the standard hard splices with independent crimp barrel and heat shrinkable tubing.

http://www.dmctools.com/Products/gmt_se ... tools.html

I worked on AH-64As back when they were trying to rid themselves of Kapton wiring. That's where I cut my teeth running new wires. I've done LOTS of battle damage repair on AH-64Ds and I have to say the Cold Applied Splice would work well when an aircraft is down in hostile territory. Other than than, Army units should have a spool of most types of wires and cables on that aircraft. Running new wire gets really easy after a while and you don't need to have any power, just a head lamp. Additionally it doesn't deplete your valuable stash of shielded cable splice kits.

We've been using a combined splice/shrikable tubing for decades, along with separates. The combined used a solid plastic sealant on each end of the heatshrink to environmentally seal the splice. Whats new with this new splice is that there is a gel at either end and does not require a heat gun to melt the plastic at the ends of the tubing.

For the F-15/F-16 world, we have been replacing the Kapton with a teflon based shielded wire. Definately lasts much longer, specially in areas where a cable might move or at connectors that have to be removed and installed numerous times, which is the main cause for Kapton breakdown.

Forum: Technology

NEW TYPE OF AIRCRAFT WIRING SPLICE