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 aircraft battery cables, illustrating their routing from the engine, through the cabin, to the rear fuselage battery box.
It details specific cable installations, including upgrading the cable from the starter solenoid to the starter and connecting to the master solenoid, while also removing unnecessary power taps.
Emphasis is placed on careful cable routing to avoid contact with sharp objects (like bulkhead screws) and inspecting connection points for corrosion.
The author recommends thoroughly documenting all replacement and routing work with multiple photographs for future reference.

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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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