Something to check on your MEP803

[DieselAddict]

As part of checking the damage on the MEP803 I picked up today I noticed something that should be resolved in the generator electrical section. The way the wires are routed from the reconnect switch to the terminals below they cross over some sharp metal edges with no protection. I can see on one wire that there is already some fraying. If that were to continue long term it could lead to a dangerous condition with the generator.

I'm going to put some rubber stripping along the two edges to give the wire something to rub against without causing damage. I'm also going to look at moving the wires around to see if I can get them away from those edges.

 

[dmetalmiki]

Maybe you could encase them in a rubber hose, split it if needed.

 

[DieselAddict]

I had thought about using a loom to wrap them. The issue you can cause there is with heat dissipation. I'll need to check the wire size and make sure wrapping it up won't cause any heat problems.

 

[robson1015]

Good eye Diesel - you really know your way around these units I can see. I see the damage area you referred to earlier. Looks like a good score.

 

[DieselAddict]

Thanks! I enjoy working on these things. I must be insane.

I had fun with this photo today. This is what the damage looked like when I picked it up from the base. When I was taking it apart I realized that someone had started to disassemble it but then stopped.

I have the external panels pretty much fixed using a rubber mallet, wood blocks and angle iron. I need to repair the corner of the bulkhead that was crushed. I'm going to try and bend it back out then reinforce it with some extra material so it keeps its shape. With any luck it should look pretty good when I'm done. I'm not going to try to hide the repair.

I'll snap a few more photos when I figure out the best way to resolve the wire chaffing issue and show how the body work is going.

 

[Chainbreaker]

For preventing wire chaffing on metal edges I would suggest using something like this (caterpillar grommet which attaches to metal edge not wire loom):

http://www.brownaircraft.com/category_s/95.htm

 

[DieselAddict]

For preventing wire chaffing on metal edges I would suggest using something like this (caterpillar grommet which attaches to metal edge not wire loom):

http://www.brownaircraft.com/category_s/95.htm

That is the plan.

 

[CT-Mike]

Thanks for the heads up Chris, I will be checking mine for the same issue.

 

[DieselAddict]

I was able to get the pucker out of the bulkhead this morning. My hats off to the craftsmen and women that can shape metal and not leave a bunch of marks behind. Obviously I'm missing that gene.

It ain't pretty but it it should line up now!

Before:


After:

 

[robson1015]

Remind me not to let you do any body work on my car....LOL Looks good compared to before.

 

[DieselAddict]

For sure not body work. I'm a crackin' mechanic otherwise.

 

[ZackMan]

DieselAddict,

Thanks for the wires identification. I just had the side panel removed in taking off he difficult fuel water/separator and recall seeing the wires you referenced. I wll take note.

 

[DieselAddict]

This is looking less crappy than I expected.

 

[Chainbreaker]

Now if you took some cleaner and cleaned up those skid marks...lol and sprayed a lil touch up paint (Rust-Oleum Camouflage Sand 263653 works well) it would hardly be noticeable. As they say..."Beauty is only skin deep".

 

[robson1015]

Yep - a little paint and good as new - nice job Addict.

 

[DieselAddict]

Now if you took some cleaner and cleaned up those skid marks...lol and sprayed a lil touch up paint (Rust-Oleum Camouflage Sand 263653 works well) it would hardly be noticeable. As they say..."Beauty is only skin deep".

Thanks for the info on the paint color. That should finish it off nicely.

 

[Chainbreaker]

Also, you could fill in those rips/tears in the metal either with a thick epoxy (JB Weld?) or perhaps bondo then lightly sand down and paint and the repair would truly disappear.

 

[DieselAddict]

I already have JB Weld at the ready.

 

[Chainbreaker]

If you've worked with JB Weld you probably already know that it likes to puddle/run. You might consider putting something behind those gaps for the epoxy to adhere to (duct tape/friction tape?). It might take several coats to get it thick enough to fill in. You should wire brush off the paint to allow a better bond to the metal in those areas and clean with acetone or alcohol beforehand. Just needs to be enough of a cosmetic fix to hold paint and not vibrate off.

 

[DieselAddict]

Oh yea, I have a merit badge in JB Weld.

The plan is to use a strip of aluminum stock on the back to bridge the cracks and give it some strength. Overkill I know but thats how it goes with me.