Matronics Email Lists :: View topic - Intercom to Radio Wiring

Matronics Email Lists
Web Forum Interface to the Matronics Email Lists

Get Email Distribution Too! FAQ Search Memberlist Usergroups Register

Profile Log in to check your private messages Log in

Intercom to Radio Wiring

Matronics Email Lists Forum Index -> AeroElectric-List

View previous topic :: View next topic

Author Message

n520tx(at)gmail.com
Guest

Posted: Mon May 05, 2014 3:01 am Post subject: Intercom to Radio Wiring

This is a question regarding technique rather than specific equipment.



I'm about to start my third try to wire my 4 place intercom to my radio.

My goal is to get all the wires at the connector to actually look

semi-decent and not the fat-collection-of-rats-nest bundle that has

resulted from my first two attempts. It CAN be done, I've seen it. I

just don't know any of the secrets ... wondering what they are ? 



Is there a technique or process/pattern to this ? With all the wires

coming in - 3 from each headset connection, 2 additional pair for ptt,

power and then the connections to the radio - there's gotta be something

I'm missing because I've seen it done nicely ...



I checked the aeroconnections site and used a couple of the tricks

there, but they really didn't get me very far.



Any advice other than hiring the task out ?



Thanks



--Ron

- The Matronics AeroElectric-List Email Forum -

Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:

http://www.matronics.com/Navigator?AeroElectric-List

email(at)jaredyates.com
Guest

Posted: Mon May 05, 2014 3:54 am Post subject: Intercom to Radio Wiring

Hi Ron, I ran into the same problem. Â This was my solution to combining the left audio, right audio, and ground signals for the right front and rear passengers:



http://jaredyates.com/bearhawk/wp-content/uploads/2011/06/P1010720.jpg 



I brought all of the incoming wires into a regular machined-pin 25-pin d-sub connector. Â Then I used an opposite-sex solder d-sub to make the one shown in the picture. Â I soldered a little piece of wire across the appropriate pins. Â I think in the final configuration I stripped a 5/8" or so long piece off of the end of a longer wire, soldered the stripped part across the cups, and then connected the other end of that wire to the intercom input. Â This would be an option if you run out of pins. Â I didn't take a picture of the final configuration, but I think I did run short of pins on at least one of them. Â When it was done I potted the whole thing to keep it from shorting. Â 

 



As for the ptt and the rest, my intercom might have been a little bit different. Â I had an input pin for each front seat occupant, so that when the right front keys, only his mic goes to the radio, etc. Â Mine were also only single wires- one end went to the intercom, then the other end went to local ground after passing through the switch.

 



Another problem was turning big shields into wires that I could crimp into machined pins. Â I used crimped on terminals of various types. Â If I had a large size change, I might crimp a yellow "handshake" connector on the big clump of shields, and then crimp a red one onto a single 22-gauge piece of wire that went to the machined pin. Â Sometimes I would bring two large clumps of shields into each end of a yellow splice, then stick a 22-gauge wire in one of the ends along with the shields. Â 

 



I'll not imply that the above is necessarily the best way- my mission wasn't to win any awards, but just to have a reliable mode of transportation- but so far it is all working just fine. Â In the end, I wouldn't say it's a rat's nest (though some might), but perhaps more of a bird's nest.

 



On Mon, May 5, 2014 at 6:59 AM, Ron Walker <n520tx(at)gmail.com (n520tx(at)gmail.com)> wrote:

[quote] --> AeroElectric-List message posted by: Ron Walker <n520tx(at)gmail.com (n520tx(at)gmail.com)>

 

 This is a question regarding technique rather than specific equipment.

 

 I'm about to start my third try to wire my 4 place intercom to my radio.

 My goal is to get all the wires at the connector to actually look

 semi-decent and not the fat-collection-of-rats-nest bundle that has

 resulted from my first two attempts. It CAN be done, I've seen it. I

 just don't know any of the secrets ... wondering what they are ?

 

 Is there a technique or process/pattern to this ? With all the wires

 coming in - 3 from each headset connection, 2 additional pair for ptt,

 power and then the connections to the radio - there's gotta be something

 I'm missing because I've seen it done nicely ...

 

 I checked the aeroconnections site and used a couple of the tricks

 there, but they really didn't get me very far.

 

 Any advice other than hiring the task out ?

 

 Thanks

 

 --Ron

 

 

 

[b]

- The Matronics AeroElectric-List Email Forum -

Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:

http://www.matronics.com/Navigator?AeroElectric-List

nuckolls.bob(at)aeroelect
Guest

Posted: Mon May 05, 2014 5:49 am Post subject: Intercom to Radio Wiring

At 06:51 AM 5/5/2014, you wrote:

  	  Quote: 	
		  Hi Ron, I ran into the same problem. Â This was my solution to combining the left audio, right audio, and ground signals for the right front and rear passengers:



  http://jaredyates.com/bearhawk/wp-content/uploads/2011/06/P1010720.jpg 	


   Looks like a good lick to me . . .



   One of my pet peeves concerning the design of many

   appliances is the dearth of pin-outs necessary

   for graceful termination of wires in a common

   installation.



   Many times it's not a big deal to the next

   larger size d-sub connector on the product to

   assist the installer in termination of multiple

   wires to grounds or paralleled loads.



   Mr. Yates' solution is a rational and robust

   solution to your installation problem . . .

   perhaps a bit more 'bulk' than soldering

   them into heat-shrink covered lumps . . . but

   certainly more elegant in appearance and

   maintainability.



 

 

   Bob . . .    [quote][b]

- The Matronics AeroElectric-List Email Forum -

Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:

http://www.matronics.com/Navigator?AeroElectric-List

tim2542(at)sbcglobal.net
Guest

Posted: Mon May 05, 2014 6:18 am Post subject: Intercom to Radio Wiring

If your using Bob's technique to terminate the shields, make the pig tails long enough so they are just outside the hood of the D-sub. The short length of un-shielded wire should not cause any problem. You can also daisy chain all the grounds into the minimum required number before it enters the hood. Otherwise there may be too much bulk to get the hood on.

Tim

 	  Quote: 	
		   On May 5, 2014, at 3:59 AM, Ron Walker <n520tx(at)gmail.com> wrote:

 

 

 

 This is a question regarding technique rather than specific equipment.

 

 I'm about to start my third try to wire my 4 place intercom to my radio.

 My goal is to get all the wires at the connector to actually look

 semi-decent and not the fat-collection-of-rats-nest bundle that has

 resulted from my first two attempts. It CAN be done, I've seen it. I

 just don't know any of the secrets ... wondering what they are ? 

 

 Is there a technique or process/pattern to this ? With all the wires

 coming in - 3 from each headset connection, 2 additional pair for ptt,

 power and then the connections to the radio - there's gotta be something

 I'm missing because I've seen it done nicely ...

 

 I checked the aeroconnections site and used a couple of the tricks

 there, but they really didn't get me very far.

 

 Any advice other than hiring the task out ?

 

 Thanks

 

 --Ron

- The Matronics AeroElectric-List Email Forum -

Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:

http://www.matronics.com/Navigator?AeroElectric-List

sprocket(at)vx-aviation.c
Guest

Posted: Mon May 05, 2014 7:39 am Post subject: Intercom to Radio Wiring

I totally agree.  One of the benefits of packaging the audio products that I have developed in d-sub backshells is that there are a lot more pins available for grounds.  In fact, I usually reserve a whole row of pins for ground, whether they are needed or not.

This simplifies installation and saves time and money.

The availability of a whole class of through-hole components that have a maximum height sized to fit in these packages makes even small volume designs feasible without having to resort to surface mount devices.

Cheers,

Vern Little

Vx Aviation



====================================================Sent from my iThing. It is responsible for all gramma and typo terrors.



On May 5, 2014, at 6:46 AM, "Robert L. Nuckolls, III" <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)> wrote:

[quote]  At 06:51 AM 5/5/2014, you wrote:

  	  Quote: 	
		  Hi Ron, I ran into the same problem. Ã‚ This was my solution to combining the left audio, right audio, and ground signals for the right front and rear passengers:



  http://jaredyates.com/bearhawk/wp-content/uploads/2011/06/P1010720.jpg 	


   Looks like a good lick to me . . .



   One of my pet peeves concerning the design of many

   appliances is the dearth of pin-outs necessary

   for graceful termination of wires in a common

   installation.



   Many times it's not a big deal to the next

   larger size d-sub connector on the product to

   assist the installer in termination of multiple

   wires to grounds or paralleled loads.



   Mr. Yates' solution is a rational and robust

   solution to your installation problem . . .

   perhaps a bit more 'bulk' than soldering

   them into heat-shrink covered lumps . . . but

   certainly more elegant in appearance and

   maintainability.



 

 

   Bob . . .     	  Quote: 	
		  



D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D

lectric-List"">http://www.matronics.com/Navigator?AeroElectric-List

D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D

//forums.matronics.com

D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D

ot;">http://www.matronics.com/contribution

D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D



	


[b]

- The Matronics AeroElectric-List Email Forum -

Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:

http://www.matronics.com/Navigator?AeroElectric-List

nuckolls.bob(at)aeroelect
Guest

Posted: Mon May 05, 2014 11:26 am Post subject: Intercom to Radio Wiring

At 10:38 AM 5/5/2014, you wrote:

 	  Quote: 	
		  I totally agree.  One of the benefits of packaging the audio 

products that I have developed in d-sub backshells is that there are 

a lot more pins available for grounds.  In fact, I usually reserve a 

whole row of pins for ground, whether they are needed or not.



This simplifies installation and saves time and money.



The availability of a whole class of through-hole components that 

have a maximum height sized to fit in these packages makes even 

small volume designs feasible without having to resort to surface 

mount devices.


	


    Isn't this business fun?

   Bob . . .

- The Matronics AeroElectric-List Email Forum -

Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:

http://www.matronics.com/Navigator?AeroElectric-List

Display posts from previous:

	Matronics Email Lists Forum Index -> AeroElectric-List	All times are GMT - 8 Hours
Page 1 of 1

Jump to:

You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum
You cannot attach files in this forum
You can download files in this forum