Photo Gallery: Replacing Your Battery Cables

A step-by-step look at replacing aircraft battery cables

Engine side view with new battery cables.
Starter solenoid with new battery cable. Not shown is the new cable from the starter solenoid to the starter that I built to replace the smaller diameter copper cable that had been installed previously. Since I had the extra cable and terminals I made a new cable. Also shown is the aluminum cables that feed the instrument buss. They were not replaced and are not called out for replacement in the service bulletin.
A close up of the starter solenoid wiring.
Cabin left side front view. Note the cable routing. Also note the fuel selector valve and static and pressure lines for the instruments that exit the left wing.
Battery cable routing. Always inspect locations for signs of corrosion.
Battery cable routing as it passes out of the cabin through the rear bulkhead. The cabin insulation ends at the bulkhead.
Another view of the cable routing in the aft section of the fuselage and battery box location.
A view of the cable routing through the rear bulkhead location. Care must be taken to secure the cable and keep it away from the screws that hold the rear bulkhead in place. Digital cameras allow multiple pictures to be easily taken for archive purposes. Don't be hesitant to take as many as possible to document your work.
Connection to the master solenoid. In the process of installing this connection, I removed some unnecessary power taps from equipment that had been removed over the years. I also discovered a loose connection to the relay that was easily fixed.
Another view of the master solenoid connection.
One big crimping tool. It's a few years old, but still works great. I hate to think what it would cost today.
A close up of the business end of the crimping tool.

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