At InterConnect Wiring, we know that military aircraft wiring harnesses are much more than bundles of wire—they’re the nervous system of some of the most advanced jets in the world, including the F-16, F-22, and F-15. But as reliable as these systems are, they don’t come without their fair share of challenges.
In this video, InterConnect Wiring Program Manager Steve Floyd breaks down some of the biggest obstacles facing military aircraft wiring—and how our team overcomes them every day to keep aircraft flying safely and effectively.
Challenge #1: Aging Aircraft & Outdated Wiring
Many of the aircraft we service are flying well beyond their original projected service lives. Over time, the Kapton insulated wiring used in older models can become brittle, corroded, or entirely obsolete. This creates real risks—including system failure or even fire hazards. In fact, it’s becoming a significant safety-of-flight concern for F-16 fleets around the globe.
Our Solution: InterConnect specializes in rewiring aging aircraft, particularly the F-16. We replace outdated wiring with TKT (Teflon-Kapton-Teflon) insulated wire, offering increased durability and heat resistance—so aircraft can continue to meet mission demands without compromise.
Want to learn more about aging insulation? Check out our Kapton wiring article here.
Challenge #2: Complex Installation & Routing
Military jets are densely packed with components—and their wiring systems reflect that. A single harness can include miles of wire and dozens of connectors, all of which need to be routed through extremely tight and confined spaces.
Our Solution: We utilize HAD (Harness Assembly Drawing) models, laser wire marking, and point-to-point layout methodology to streamline the production process. This ensures that every harness is custom-built to exact aircraft specifications and is ready for efficient installation once it leaves our facility.
Challenge #3: Meeting Stringent MIL-SPEC Standards
From intense vibration and temperature fluctuations to electromagnetic interference, military harnesses are exposed to harsh operating environments. To ensure performance and safety, every wiring harness must pass rigorous testing under military specifications.
Our Solution: Each harness is put through a comprehensive testing process including:
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Continuity and insulation resistance
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ESD and bonding
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Fiber optics dB loss
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Isolation and Hi-Potential testing (up to 1,500VAC and 1,000VDC)
This ensures that our harnesses meet or exceed MIL-SPEC requirements—because the mission depends on it.
Keeping Aircraft Mission-Ready
From outdated wiring to complex layouts and strict testing standards, wiring harness challenges are no small feat. But at InterConnect Wiring, our team is committed to providing innovative solutions that keep military aircraft mission-ready.
Watch the full video to hear directly from Steve Floyd, and don’t forget to subscribe to our YouTube channel for future updates, tutorials, and behind-the-scenes content.
