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====== TA-4 Console Lights ======

===== Complaint =====

The overhead console lights were working only intermittently. The checklist suggesting grounding problems.

===== Work Notes =====

Examined the console lights which are located in the cockpit canopy. As suggested, the lights were working intermittently, and would turn on or off by handling them. Noticed that the metal bracket that holds the light sockets were painted black, preventing a good ground.

While handling the light sockets and removing the black paint, one of the sockets came separated from its wire. When re-soldering, dropped the terminal somewhere into the rear seat mechanism. Didn't recover it, so created new one from some small copper pip.


Note that the bracket is painted black. Needed to remove the paint for a good ground.
{{:projects:a4work:20190104_133501_r.jpg|Console Socket Bracket}}

Created this terminal from small copper pipe. Soldered a small disk to it.

{{:projects:a4work:20190105_224846_r.jpg|Socket Tip Terminal}}

Note that the shade part (containing the glass) just pulls off. No tools are necessary.

{{:projects:a4work:20190104_131423_r.jpg|Console Light Socket Components}}

Showing partial removal of black paint.

{{:projects:a4work:20190104_132641_r.jpg|Console Socket Bracket Right Side}}

Assembled terminal end, ready to screw onto socket.

{{:projects:a4work:20190108_154436_r.jpg|Assembled Socket Terminal}}


===== Solution =====

Created a new terminal tip conductor from small copper pipe. Purchased a white nylon bushing of the proper size at Ace Hardware for $.37. Sanded it, reducing its diameter to fit. Soldered new tip conductor to wire in canopy, a two-man job to prevent dropping anything. Added heat shrinkable tubing to prevent shorts.

1/8/2019.
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