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Wiring Harness Inspection - Oct. 3rd, 2025

Overview

Went out to test our skills in identifying different characteristics of a wiring harness, along with potential hazards that could come from imperfections in the harness. I took shots of a harness from a F109-GA-100 engine. This engine is out of commission, due to it being a display model, but I believe it’s a good representation of the FAA standards are for when it comes to wiring harnesses.

Resources

FAA AC 43.13-1B - Chapter 11, Sections 8-12

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Report of Findings

Photos

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Fig. 1: Connector

Fig. 1: Connector

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Fig. 2: Harness Leads

Fig. 2: Harness Leads

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Fig. 3: Harness Joint

Fig. 3: Harness Joint

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Fig. 4: Connector side of Harness

Fig. 4: Connector side of Harness

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Inspection Report

Fig. 1: Connector

Circular connector looks in really good shape with still maintaining a strong connection with the internal pins. The compression ring isn’t loose and will ensure a proper fit and strong electrical connection. Near the outside of the connector there was small single strands of frayed wire, and that is part of the shielding that protects the wire. This may need to be replaced or at least checked to ensure that won’t compromise the integrity of the connection. All of this is due to the fact that this harness is exposed to extreme heat at all times.

Fig. 2: Harness Leads

Harness leads look in really good shape with nothing super notable about them. The only thing that is really worth mentioning is the connection points may have a buildup of corrosion from sitting around for so long. This could lead to a failure in that connection and potentially cause water, or other elements, to leak through. There is also some fraying starting which again could become something serious, but as of right now it shouldn’t be that much of a concern.

Fig. 3: Harness Joint

The harness joint is where things really started to get interest! Not really, just mainly there was more fraying. This could be mainly due to the fact that there would be consequentially the most amount of movement at this point. This is from the aircraft's movement and jostling around the internal wires. Ensuring that the shielding is up to spec is essential because if an internal wire is frayed it could lead to a fire, short, or several other problems. This joint look overall really good with great contact around the wires and a snug fitting.

Fig. 4: Connector Side of Harness

The connector side of the harness looks really good, and nicely packed. The neat organization would make problem solving extremely easy and would lead to less connections compromised! Both connection leads were in very good shape, with some fraying, but nothing to raise concern over. There was no buildup of corrosion for the elements, which is another good sign of proper sealment of wires. There was also no burning from exposed wires shorting anywhere across the harness. Overall, I’d give this a pass with maybe an FAA inspector to ensure everything was in order.

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