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Mission Statement 

The purpose of FLAPS-2-APPROACH is two-fold:  To document the construction of a Boeing 737 flight simulator, and to act as a platform to share aviation-related articles pertaining to the Boeing 737; thereby, providing a source of inspiration and reference to like-minded individuals.

I am not a professional journalist.  Writing for a cross section of readers from differing cultures and languages with varying degrees of technical ability, can at times be challenging. I hope there are not too many spelling and grammatical mistakes.

 

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I use the words 'modules & panels' and 'CDU & FMC' interchangeably.  The definition of the acronym 'OEM' is Original Equipment Manufacturer (aka real aicraft part).

 

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Journal Archive (Newest First)
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Saturday
Feb152014

Ferrules 

What are ferrules some of you may ask – no they are not the undesirable neighbors that play loud music and park old cars in front of your house; they are called “feral”… 

A ferrule is a small electrical connector that comes in a variety of different sizes that is very handy when connecting electrical wires.  The metal needle of the ferrule is hollow allowing you to fit the correctly sized wire for maximum connectivity and faithful conductivity.

Solid Connection

Once well into building a simulator, the connection of wires to interface cards, power supplies, terminal blocks, etc becomes common place.  Having a method to easily secure wires that ensures reliability is a great asset.

Whilst you can solder wires to the above items it is often necessary to remove a wire for testing purposes or to add an additional function to the connection.  Twisting and clamping the wire beneath the screws or screw tab while functional, is far from tidy and eventually the wire will become damaged with loose wire strands. 

Loose and damaged wires can translate to poor connectivity leading to frustration when something does not work correctly.

A ferrule can easily be attached to the end of a small wire (22 gauge) and crimped.  The ferrule needle can then be cut to size to fit into an interface card or terminal block.  As ferrules come in a variety of colour-coded sizes they can be used for a variety of wire gauges.

A special crimper tool is used to 'crimp' the ferrule in place securing the wire.

LEFT:  1mm red ferrules connected to a terminal block.  They look neat, protect the wires and allow for easy removal without damage to thin wires (click to enlarge).

I’ll submit that ferrules are not suitable to use everywhere; however, for certain applications they are useful to have in your simulator-building toolkit.

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Reader Comments (4)

I want to thank you for the time you put into this website. It is an excellent resource.

Ferrules are new to me. I will give them a try as wire often gets twisted and gnarly when you push it into connectors.

February 15, 2014 | Unregistered CommenterThomas Sherry

Great idea..... I will try them. I see you can buy them on e-bay very cheaply. Thank You

February 15, 2014 | Unregistered CommenterJames Menne

I have not thought to use these in the way you suggest. A good idea. Love Fiona

February 15, 2014 | Unregistered CommenterFiona Morton

I have been a fan of your site the beginning - great site with a good cross section from training to building and general interest.. I will try ferrules based on your recommendation. What a good idea. Regards Peter

February 15, 2014 | Unregistered CommenterPeter Coleman
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