Harness & Wiring
Wire Harness Repair & Manufacturing
Repair, rebuild and complete remanufacture of aircraft wiring harnesses — including assemblies that are no longer available to buy.
Overview
When the harness is the problem
Wiring is behind a surprising share of faults blamed on avionics, and a damaged or obsolete harness can ground an aircraft as effectively as a failed computer. On older aircraft the original assembly is frequently no longer available at any price.
Building a replacement to drawing is often the only route, and it is usually far cheaper than the alternatives. Harnesses are labelled and bench-verified before they go anywhere near the aircraft.
What You Get
How we approach it.
Four things that shape the work, and that you can hold us to on any job.
- 01
Built to drawing
Assemblies made to the correct configuration, with the right wire, connectors and terminations.
- 02
Obsolete assemblies remade
Where the original harness can no longer be sourced, we manufacture a replacement.
- 03
Labelled properly
Clear, durable identification so the next person to open the panel is not guessing.
- 04
Verified before fitting
Continuity and function checked on the bench, not discovered on the aircraft.
Components
What this covers,
by component.
Jump straight to the family your unit belongs to — each page lists the equipment and the faults we see most.
Process
How the work runs
Every job follows the same four steps, so you always know which stage yours is at.
- 01
Assess & define
Inspect the existing harness or drawing and agree exactly what needs to be made or repaired.
- 02
Materials & preparation
Correct wire, connectors, backshells and protection selected for the application.
- 03
Build or repair
Assembly routed, terminated, protected and labelled to the agreed configuration.
- 04
Test & deliver
Continuity and function verification, documentation, and delivery ready to install.
Common Questions
Asked before
most enquiries.
- Can you make a harness that is no longer available?
- Yes — on older aircraft that is most of them. A replacement is manufactured to drawing with the correct wire, connectors and terminations, then labelled and verified before it goes near the aircraft.
- How do I know the harness is the problem?
- Classic signs are an intermittent that moves with airframe flexing, a fault that changes when a connector is disturbed, or a line-replaceable unit that keeps testing serviceable. Any of those is worth investigating at the harness before replacing another box.
- Do you repair harnesses, or only replace them?
- Both. A localised problem — a chafed conductor, a corroded pin, a damaged backshell — is a repair. Widespread deterioration is usually better solved by remanufacturing the assembly, and we will tell you which situation you are in.
Also Available
Related capabilities.
Most jobs touch more than one of these. We handle them under one point of contact.
Next Step
Need wire harness repair & manufacturing?
Tell us the aircraft.
Send the aircraft type, the symptom and the part number if you have it. We will come back with the realistic options.