Ignition and Electrical Component Safety!

Two grommets are being used for the ignition cables as well as the red sensor lead on my Comp-ARF Edge 540's DA 120 Engine.
When I build an airplane, I always spend extra time to ensure that all internal components are installed properly and well-secured, whether I am building a .25-size glow-powered model, or a 170cc giant-scale aerobat!

This time, we will take a look at my ignition installation on my 2.6m Composite-ARF Edge 540. This is an all-composite aircraft that is powered by a Desert Aircraft 120cc engine. Since this is a composite airframe, it has a few unique areas. For example, the motor dome is a part of the fuselage, which saves weight and ensures proper alignment of the firewall.

After my engine was mounted, it was time to secure the ignition. I opted to secure the ignition inside the fuselage. Resulting, I would have to make a few openings for both the pick-up sensor as well as the ignition shielded plug wire.

Before I got started, I made a trip to my local hardware store and purchased two rubber grommets that were large enough for the shielded plug wire as well as the pick-up sensor lead. Then, I went to a local electrical store and purchased plastic “spiral wrap” insulation to cover the shielded plug wires. Now, it was time to get back to the build!

I used a Dremel and made two openings on the fiberglass skin so that pick-up sensor as well as the ignition shielded plug wire could be inserted through. I then glued in the two rubber grommets in place using Zap Goo. Once cured, I inserted the shielded wire and pick-up sensor through the grommets. Now, no matter how much vibration existed, these electrical components would not become cut!

Updated: July 15, 2015 — 3:56 PM


  1. Very creative and yet elementary. It is often the simplest things like not properly securing components that can lead to disaster.

  2. Anytime you have a line running through a firewall, be it an auto or airframe, it is Mandatory to install grommets! They’re cheap an will avoid a pile of toothpicks.

  3. Hi John, I have just written an article about Avionic gremlins, and in it I talk about setting up your wireing systems within your aircraft to prevent crashing at the field.You are right in the fact you need to set things up right.

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