Expert: Marc Ebelini - 2/6/2010

Question
Hi, I just bought a 1975 Skyhawk with only a portable Intercom and a mish-mash of external wires, connectors, and PTT to make it all work. I want to replace with a PS Engineering Audio panel and then install a MIC & HEADSET jack pair for pilot and co-pilot. What is the best MIC & HEADSET jacks (brand) money can buy and where can I get them? I want to eliminate all potential for corrosion (salt air), noise, and wear. Thanks.

Answer
Mil spec aircraft radio jacks and plugs were usually made of brass. It's all in the plating used in making cheaper hardware. In many cases the hardware would look good but the plating conductivity was poor. Brass was good because it could be easily polished to return better conduction. Here is a site that based on their prices should be a quality product. http://www.acousticom.com/product.php?cat=connectors
If corrosion is a concern also use a fine stranded tinned wire. Be careful PVC wire is not approved for aircraft. The fine stranded wire is less prone to wire fatigue and better conductivity. If I remember correctly 22 gauge came in 7X28 or 9X32. Meaning 7 conductors of 28 gauge wire a compared to 9 of 32 gauge. Use a good grade of solder 60/40 and sleeve the connections with shrink tubing to minimize shorting. Now this may surprise you. Use at least a fifty watt soldering iron. You need to get the connection as hot as possible quickly as to not damage the wire or connectors. Make sure the iron tip is clean and tinned to conduct the heat better. Seeing a nice silver looking connection means you have not overheated the solder. If it's gray looking you applied the heat too long that allowed the solder to oxidize.
Good luck