DC Power Cable Layout

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The diagram above is provided to assist builders in visualizing the various cables that may be required for their aircraft.

Ordering ProCraft Battery Cables

Gauge

Specify the required wire gauge (AWG) for each cable, i.e. AWG-2, AWG-4, or AWG-8.  Note: It is acceptable to substitute the next larger cable if called out gauge is not available, or you want to build-in capacity for future expansion.

Length

All cable measurements will be specified from center to center on the terminal lugs.  All cables must be specified in WHOLE INCHES, (no fractional values.)  Cables will be fabricated to the following tolerances:  -0.0", +0.5"

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Make sure you have most of the major components (fuse blocks, batteries, solenoids, etc.) located and installed. 

Route a stiff rope or light weight plastic tubing along the intended path for each cable in your electrical system.  Use wire ties or temporary clamping to make your routing and measurements as accurate as possible.

Take measurements from mounting stud to mounting stud.  Record cable length requirements in ONE INCH increments (whole numbers only, please).

You may want to consider "rounding up" to the next inch, or adding an additional inch to the overall cable length.  This will allow for flexibility in the future.  For example, if an alternator is changed and has a different stud size.

Color

Heat shrink can be either red (+) or black (-) to facilitate color coding for power and ground cables.

Choosing the Right Terminal Lug

Determine stud size for EACH end of EACH cable. WE have entered a "DEFAULT" lug on the order form which is often found on appliances such as batteries, solenoids, and alternators.  YOUR requirements may differ!  VERIFY the "Default" lug is correct for YOUR application.  If it is NOT correct, be sure and make the change on the order form.  (See Example 2 on the order form.)

Terminal Lug Clocking

#2 or #4 AWG ProCraft Cables less than 18 inches in length can be very stiff and difficult to twist.  These cables may need the terminals to be orientated ("clocked") relative to one another to ease in final installation.  Please see clocking guide below for clarification.  If no clocking is specified, terminals will be oriented in same plane to each other.

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Cable/Wire Pricing:  Price per inch can be found at the top of the order form.  Multiply the length of each cable by the appropriate price per inch and enter this into the "Extended Price" column.  For each cable, add $9.00 (for "Lugs and Labor") and enter total in "Assembly Price" column. 

How to Order

The order form can be filled out online.  However, we suggest you do the following:

  1. Print a blank order form and fill it out in the shop as you're making your measurementsl
  2. Return online and fill out the order form.  This will help limit errors due to difficulty in reading some handwriting.  (not yours, of course!)
  3. Print 2 copies so you'll have one to reference should be have any questions.
  4. Checks should be made payable to SafeAir1. (Personal checks are fine)  We do NOT accept credit/debit cards.
    Mail this form with enclosed payment to:
    SafeAir1
    1540 Keller Pkwy
    Suite 108 Box 144
    Keller, Texas 76248

    NOTE:  All ProCraft Cable and Wiring assembly orders are built in batches for efficiency.  Orders will ship twice monthly; on the 1st and 15th (Or first business day thereafter.) 

DC Power Cable Layout