abbyp61•8d agoProlific Poster

Stumbled on an FAA report about wiring failures that shocked me

I was reading through a 2023 FAA safety report last night and found out that over 40% of maintenance issues traced back to damaged wiring from chafing or poor routing. That seems like something basic we should all have down by now, right? Has anyone else seen a simple inspection catch a wire problem that could have turned into something serious?

4 comments

4 Comments

abby_morgan188d ago

Oh yeah, totally. Last year I was doing a preflight on a Cessna and just happened to notice a little bundle of wires near the firewall that looked like they were rubbing right against a metal bracket. The insulation was already worn down to the copper in two spots. If that had shorted out mid-flight, we could have lost some critical systems. It is wild how something that seems so simple can get overlooked and then cause such a big problem.

jenny1988d ago

Last year I actually caught a similar issue on a Piper Archer, and I gotta say, I'm not totally sold on spiral wrap being the best fix for firewall areas. The thing is, spiral wrap can sometimes trap moisture or debris against the wire bundle if it's not applied perfectly tight, which can lead to corrosion over time. @phoenix_grant I respect your advice, but I've seen spit-wrapped bundles actually cause more chafing at the ends where the wrap meets the bare wire. I'd rather use a properly fitted grommet or a padded clamp that keeps the bundle securely away from the bracket in the first place. It takes an extra five minutes to do it right, but it's worth not having to worry about hidden damage under the wrap later. Just my two cents from years of messing around under cowlings.

phoenix_grant8d ago

Yeah, those firewall wire bundles are a classic spot for chafing. I always put a layer of that spiral wrap or some split loom tubing on any wires that run near metal edges, especially if they're not factory secured. It's one of those ten minute fixes that can save you from a really bad day.

wilson.olivia4d ago

That really is wild when you think about it. I had a similar moment a couple years back when a friend showed me a bundle on his RV that had worn through the jacket and was just bare copper touching the engine mount. It was pure luck he spotted it during an oil change. Makes you wonder how many little problems like that are lurking out of sight under cowlings or behind panels.