Photo Gallery: Replacing Your Battery Cables

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

Tuesday, October 31, 2017 at 08:11 AM ET

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Key Takeaways:

The article visually documents the process of replacing battery cables in an aircraft, from the engine and starter solenoid to the master solenoid and battery box.
It illustrates careful cable routing through various sections of the aircraft, including the cabin and rear bulkhead, highlighting the need to secure cables properly.
Key aspects of the task include inspecting for corrosion, using appropriate tools like a heavy-duty crimping tool, and thoroughly documenting the work with photographs.
The project also involved improvements such as upgrading a cable's diameter, fixing a loose connection, and removing unnecessary power taps.

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Starter solenoid with new battery cable — 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.

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