Got chewed out by an FAA inspector over my wire bundle lacing

He told me my spacing was inconsistent and pointed out a spot where the tie was tight enough to cut into the jacket on a 24-gauge line. Now I'm using a spacing gauge on every bundle and leaving a little slack with the lacing tape - anyone else had an inspector call out something you thought was fine?

4 comments

4 Comments

theajohnson20d ago

It is funny how life works-the same kind of nitpicking that drives you nuts on a wiring bundle is exactly what keeps your car from catching fire or your coffee maker from shorting out.

nina_taylor20d ago

Your spacing was inconsistent" - man, that is the kind of nitpicking that drives me up a wall. Honestly, I think the FAA guy was totally in the right here. You should be glad he caught that tight spot on a 24-gauge wire because that could have turned into a short or a fire down the line. I see guys all the time who think lacing tape is just for looks, but it's actually safety critical, and if you can't keep your spacing even, that means you're rushing the job. A spacing gauge is a crutch, not a fix - learn to do it by feel and eye so you actually get good at it instead of relying on a tool for something basic.

kai_burns7320d ago

Man, I’ve been there with a 12-gauge bundle where the inspector pulled out his own caliper and measured every single tie. He found three that were off by less than a 16th of an inch. I felt like an idiot, but honestly, @nina_taylor is right about learning the feel of it over time. A spacing gauge is a good training wheel, but once you’ve done a few hundred bundles, your hands just know where the next tie goes by eye. I ended up switching to a waxed cord instead of tape, since it lets me adjust tension way easier without digging into the jacket.

miller.diana20d ago

Oh boy, here we go again with the spacing gauge debate! I'm going to push back a little here. I've been doing this work for over 20 years and I still use a spacing gauge on every single bundle over 10 wires. Why? Because your hands get tired, your eyes get tired, and you make mistakes. I've seen too many "experienced" guys with sloppy work that they swore was perfect until a second set of eyes caught it. A gauge isn't a crutch, it's a way to hold yourself accountable for consistency. And honestly, if a FAA guy is going to measure every tie on a bundle, you better believe I want a tool helping me stay straight.