My bulkhead connector (engine side) fix due to missing pins and cracks

[Oliver S.]

Three years ago I discovered by chance that 2 or 3 pins of the bulkhead connector were missing. Not only this ... there were also cracks and despite the 2 plugs held, I wasn't comfortable with driving like this. Since a replacement of the complete bulkhead connector requires much effort I decided to use a self-devised fix:
I took measurements and - based on them - have a double T like base plate with 4 protruding pins 3D printed with DuraForm PA - colored in black. I deliberately broke off the old remaining pins and glued the printed part between the sockets on the bulkhead with a 2 component glue for PE, PP, POM and hard to glue substrates since I didn't know what exact plastic the bulkhead is made of.
Attached is a file containing the design in a format to be 3D printed, but you must rename the file to bulkhead.stl. In order to view it online you may use https://www.viewstl.com/
The pins are a bit longer than the original ones on the bulkhead. But the plugs hold and can't fall of.

Oliver

[Mark F.]

Re: My bulkhead connector (engine side) fix due to missing pins and cracks

...Attached is a file containing the design in a format to be 3D printed, but you must rename the file to bulkhead.stl. In order to view it online you may use https://www.viewstl.com/ The pins are a bit longer than the original ones on the bulkhead. But the plugs hold and can't fall of. Oliver

Very cool what you did, Oliver!

I did as you said above - and is this what your part looks like?
3D print of bulkhead connector.jpg

[Oliver S.]

Re: My bulkhead connector (engine side) fix due to missing pins and cracks

Yes! I sent this file to a 3D printing company and after checking the fitting including a bit of removing a bit material here and there, it could be glued onto the bulkhead connector.

[Frank D.]

Re: My bulkhead connector (engine side) fix due to missing pins and cracks

Clever - and useful if it holds. I just "repinned" the damaged connector housing with a replacement housing from Lectric Liimited.
But you're right - if I hadn't had experience as an avionics tech "back in the day" I wouldn't have tried it.

[Oliver S.]

Re: My bulkhead connector (engine side) fix due to missing pins and cracks

Frank: Right after posting my topic I found yours
I contacted the 3D printing company which material to use for the 3D printing best suited for application in the engine bay. Regarding the unknown plastic type of the bulkhead I assumed the most challenging with respect to adhesion and was provided with a suitable glue by a vendor.
The 3D print and glue cost about $100. Not that cheap but very easy to install.

[Frank D.]

Re: My bulkhead connector (engine side) fix due to missing pins and cracks

Don't get me wrong, if that 3-D fliz works it'll be a boon to a lot of owners that have suffered the issue where those 60 year old bulkhead connector male tabs break off from manipulation or just age.... Looks to me like there is room for some small screws as a "belt and suspenders" supplement to the adhesive.

[Oliver S.]

Re: My bulkhead connector (engine side) fix due to missing pins and cracks

@Frank: sure! If it were to fall off I would think about an improvement and screws might be an option indeed.
I’m not sure if my description is clear with respect to that all was done without removing the bulkhead connector … no hassle with working under the dash board.
I assume using screws in case the adhesive fails, would require removal of the bulkhead connector in order to drill precisely. I’m not sure if this can be done from the engine bay side with the connector still in place.