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Figure 1: Bonding
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2. Description
Figure 1 shows the bonding installation in the airplane.
The copper tape in the fuselage makes a loop. One end of the loop connects to the firewall at a
feed-thru connection. The engine bonding wire connects to the feed-thru connection on the front
face of the firewall. The other end of the loop connects to the right side of the firewall in the same
way.
The copper tape goes along each side of the fuselage. The side tapes are connected by a piece of
copper tape on the forward face of the B-bulkhead. Pop-rivets attach faston tabs to each end of the
tape on the B-bulkhead. Jumper wires connect the faston tabs to the 2 copper tapes which go aft of
the B-bulkhead.
Bonding jumper wires connect to all main metal components. Pop rivets through the structure and
the copper tape hold faston connectors. The jumper wires attach to the connectors.
Copper tape also makes the ground planes for antennas. The strips of copper tape over-lap each
other. The conductive adhesive for the tape bonds the strip together. It also bonds the ground
plane to the bonding loop.
You can test the bonding system like other bonding systems. The maximum resistance values
between connection points must not be more than standard bonding connection tolerances.
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MAINTENANCE PRACTICES
1. General
This Section tells you how to repair copper tape (or how to install new copper tape) and bonding
tabs. It also tells you how to test the bonding system.
Aluminum touching copper causes corrosion. Protect areas where aluminum touches copper tape.
Use a material which prevents a reaction between aluminum and copper. The material must
conduct electricity. Use one of the following or an equivalent product:
− Noalox (Ideal).
− Penatrox (Burndy).
The edges of copper tape which touch GFRP can lift. Apply a moderate amount of 189 contact
adhesive (Ontario Rubber, Mississauga, Ontario, Canada) with a brush. Cover the top of the tape
and the GFRP for 25 mm (1 in) each side of the join.
Apply protective coating to the base of a tab which overlaps the copper tape. Use NYCOAT 7-11
(Nycoat laboratories, North Hollywood, CA) or an equivalent product.
2. Repair/Install New Copper Tape
Repair copper tape by bonding new tape over the damaged area.
A. Material
Items Quantity Part Number
Copper tape (3M). A/R 1181
Industrial alcohol. A/R Commercial
189 Contact adhesive or equivalent. A/R Commercial
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B. Repair/Installation Procedure
Detail Steps/Work Items Key Items
(1) Clean the area where adhesive will touch. Remove all dirt, oil and resin.
(2) Immediately before applying tape (or making
contact with electrical connections) clean the
surface with alcohol.
Use alcohol or an equivalent cleaning
solution.
Note: If necessary, remove the resin from the edges of the copper tape. This will
make sure that over-lapping tape will make a good contact.
(3) Apply copper tape to overlap existing tape. The overlap must be at least 12 mm
(0.5 in) along the length of the new tape.
(4) Apply more tape as above until you have
covered the area.
(5) Apply 189 contact adhesive to the top of the
tape and the GFRP where they join.
Use a brush to apply the adhesive for
25 mm (in) each side of the join.
(6) Do a bonding resistance check.
3. Replace/Install New Bonding Tabs
A. Material
Items Quantity Part Number
NYCOAT 7-11. A/R Commercial
Industrial alcohol. A/R Commercial
B. Procedure
Detail Steps/Work Items Key Items
(1) Remove the loose tab.
(2) Clean the area where the new tab will touch. Remove all dirt, oil and resin.
(3) Apply protective coating to the base of a tab
which overlaps the copper tape.
Use NYCOAT 7-11 or an equivalent
product.
(4) Do a bonding resistance check.
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CHAPTER 24
ELECTRICAL POWER
Electrical Power
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