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Lane A errors were appearing at different phases of flight.  It listed in the report Ignition Cylinder 1/2 or Ignition Cylinder 2/3.  Did not have the BUDDS Dongle so found a local technician to download the files from the engine.  The data was gone over and these connectors appeared to be loose with more errors than I thought had happened.  The fix for a certified engine would be to replace the Faston connectors. This is quite expensive.  To change it over to Tyco connectors the coil packs and wiring harness needs to be replaced all together,  Since my system is experimental it was suggested that I clip off the Faston connectors and solder the wires directly to the coil packs.  I did this along with using shrink tubing that contains a hotmelt glue to make the connections stable.  Test flights have shown that this fix is working but wish the other connectors were on the engine to begin with.  If I have a problem with a coil pack, it should be simple to desolder and resolder a new one in.

10994_1_IMG_5535.jpg (You do not have access to download this file.)
10994_1_IMG_5532 2.jpg (You do not have access to download this file.)
  • Re: Faston Connectors on Coil packs

    by » 3 weeks ago


    Faston connectors, if quality units from a US manufacturer, are very reliable and handle vibration well.  They generally don’t fail unless they have been installed and removed many times or installed improperly.  If misaligned and forced onto the spade at an angle, the ears can be sprung open a little and they won’t hold well.  Generally, this is easily corrected by slightly squeezing the connector using Vise-Grips.  Pliers are trickier as you can easily squeeze the contacts completely closed making them very hard to install.  Vise-grips allow you to squeeze a controlled amount and close the contacts just enough to tightly hold onto the spade terminal again.

    Not sure who suggested soldering, but that is very bad advice for this application.  Solder will stiffen the wire and create a stress concentration at the end of the solder wick that will break the wire from vibration.  Much better to either fix the faston with vise-grips or, if the connector is damaged beyond repair, cut it off and crimp on a new one.


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