Shielding Fix

Ignition Shielding Replacement - DA50, 60, 70, 85, 100, 120, 150, 170, 200, 215

Your Desert Aircraft Ignition shielding can be replaced in a few minutes using a pair of wire cutters, a sharp knife or razor, and pliers- you can also use a pair of ear clamp pliers for the ear clamp, but regular pliers will work fine. This is not compatible with the DA-35 ignition. 

1. Disconnect all power to the ignition. Begin by cutting the red heat shrink away from the ignition cap using caution not to damage the ignition cap. You can use a heat gun to help soften the heat shrink for easier removal. CAUTION: Avoid damaging the high voltage wire inside.

2. Once the heat shrink has been removed, separate the ignition cap and high voltage wire by pulling with a good firm tug. 

3. Remove the heat shrink from the flange on the ignition and begin cutting away the damaged shielding wire. CAUTION: Avoid damaging the high voltage wire inside.

4. Using a razor blade, light sandpaper, or a lightly abrasive pad, clean up the surface of the flange on the ignition. IMPORTANT: This step ensures the shielding wire will have a good ground.

5. Use a pen or screwdriver to help spread the end of the shielding sleeve open. If the ends are heavily frayed, use a pair of wire cutters to trim off only the frayed parts to make this step easier- do not cut an excess off. 

6. Once the shielding sleeve has been spread open, begin pushing the high voltage wire into the shielding. 

7. Slide the shielding sleeve all the way over the flange on the ignition, leaving roughly a 1/8" gap between the box and the shielding. Slide the ear clamp and the smaller heat shrink tubing onto the wire. 

8. Slide the ear clamp over the flange on the ignition box ensuring the shielding wire is seated between the ear clamp and the flange on the ignition box. Crimp the ear clamp in place on the edge of the flange making sure there is approximately a 1/8" gap between the ignition box and the shielding sleeve. 

9. Slide the heat shrink over the completed assembly and shrink in place using a heat gun, ensuring the heat shrink is seated up flush against the ignition box. 

10. There will be an excess of shielding sleeve in most instances. Spread out the shielding wire so that it is flush with the high voltage wire and that there is no bunched up areas of the shielding sleeve. Trim off the excess shielding sleeve with the end of the high voltage wire. 

11. With the shielding sleeve cut flush with the end of the high voltage wire, trim back approximately 1/4" to 1/2" of the shielding sleeve. 

12. Slide the remaining ear clamp and the larger piece of heat shrink tubing onto the wire. 

13. Using a razor blade, light sandpaper, or a lightly abrasive pad, clean up the surface of the flange on the ignition cap. IMPORTANT: This step ensures the shielding wire will have a good ground.

14. Firmly insert the high voltage wire into the ignition cap, ensuring it seats fully into the diode inside of the ignition cap. Slide the shielding sleeve over the end of the ignition cap, and slide the ear clamp over the assembly ensuring the shielding sleeve stays tight to the entire wire and cap assembly. Crimp the ear clamp in place.

15. Slide the heat shrink tubing over the completed assembly and use a heat gun to shrink in place.