Military Aircraft Wiring Harnesses: Challenges & Solutions
Posted by Steve Floyd on March 18, 2025
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 • Read More >>
Topics: Aero Precision, Aerospace, Aerospace Industry, Aerospace Vehicle, Aircraft Rewiring, Cockpit Panels, Connectors, Defense Aviation, Electrical Harnesses and Panels, Engineering, Engineering Design, F-15, F-16, F-16 Electrical, F-16 Electrical Wiring Harness, Harness Assembly, Heat Shrinking, How Built, Insulated Wire, InterConnect Wiring, Kapton, Kapton vs TKT, Kapton Wire, Laser markable MIL Spec Wire, Laser Wire Marking, Machine, Manufacturing, MIL-W-5088, Military Aircraft Rewire Decision, MRO, Quality, Regulation, Repair, Rewire, Science, Specification, STEM, System Diagram, Technology, Testing, VLOG, Wire, Wire Identification, Wiring Harness, Wiring Harness Design
Post Conference Report: F-16 TCG WWR
Posted by Joseph Rodriguez on September 21, 2021
My. name. is. Robot. Joseph. My. purpose. is. to. give. Post-Conference. Report. for. 2021. F-16. TCG. WWR. I was manufactured to prevent Electrical Wiring Interconnect System (EWIS) issues by spreading knowledge. Earlier model referred to as Robot John. Post-Conference Report Part 1: Video of Robot John, Clare McGarrey and Kristin Boyd giving presentation at F-16 • Read More >>
WHAT IS CROSSLINKED TEFZEL INSULATED WIRE AND SPEC 55 WIRE?
Posted by Colton Peel on May 18, 2021
Some of our blogs in the past have focused on Kapton insulated wire and TKT insulated wire. This time we will discuss a different type of wire used on F-15 and F-18 military jets as well as commercial aircraft including the Boeing 737, 747,757, 767, and 777 as well as the Airbus A320, A330, A340 • Read More >>
Topics: Aerospace, Blog, Boeing, Crosslinked Tefzel, Electrical Harnesses and Panels, F-16, F-16 Electrical, How Built, Insulated Wire, Kapton, Kapton vs TKT, Kapton Wire, Rewire, Spec 55 Wire, Support, Technology, Testing, Wire, Wiring, Wiring Harness, Wiring Harness Specification, Wiring Harnesses
What Are the Disadvantages of Kapton Insulated Wire?
Posted by Marc Piloian on March 23, 2021
Hello readers! Today, we will present information about the Disadvantages of Kapton Insulated Wire (tap here to read about the Advantages of Kapton insulated wire). After years of use in many different civilian and military platforms including the F-16, UH-60, AH-1, F-15, and F-18, serious safety issues began to appear. Once the Kapton wire was • Read More >>
Topics: Arc Tracking, Blog, Kapton, Kapton Wire, Manufacturing, Safety, Technology, Testing, Wire, Wiring
InterConnect Releases New eBook!
Posted by Clare McGarrey on March 26, 2018
Kapton Wire, TKT, Aircraft Rewire & Refurbishment This E-Book is a compilation of the informative articles InterConnect Wiring has published over the past year and covers these main topics: 1) Kapton Wiring: The Good, The Bad, and The Ugly, 2) Rewire Programs: The Whole Kit and Kaboodle, and 3) Refurbishment Programs: Why Buy New When • Read More >>
Topics: Blog, Kapton, Kapton vs TKT, Kapton Wire, Wiring Harnesses
Arc Tracking of Kapton Insulated Wiring Versus TKT
Posted by John Ashour on February 13, 2018
Who is the biggest loser? TKT Insulated Wire or Kapton Insulated Wire? How does arc tracking of F-16 TKT wiring harnesses compare to F-16 Kapton wiring harnesses? This article includes videos too! Most of InterConnect’s blogs in 2017 were about F-16 Kapton insulated wiring. We discussed many things about Kapton wiring including: (1) which • Read More >>
Topics: Blog, Kapton, Kapton vs TKT, Kapton Wire, Wire, Wiring, Wiring Harnesses
What is the Priority List of Wiring Harnesses to Replace on 20-Year-Old F-16’s?
Posted by John Ashour on February 5, 2018
InterConnect’s previous article described which areas inside an F-16 house the most problematic wiring harnesses. The purpose of this article is to get more precise by listing F-16 wiring harness part numbers as well as the areas they are generally located. InterConnect offers many wiring harness replacement programs, sometimes calling them rewire programs. InterConnect’s most • Read More >>
Topics: Blog, F-16, F-16 Electrical Wiring Harness, Kapton, Kapton Wire, Rewire, Wire, Wiring, Wiring Harnesses
What are the MTBF Recommendations for F-16 Wiring Harnesses?
Posted by John Ashour on January 15, 2018
This blog is a detailed one and InterConnect is going to do something that never has been done before! InterConnect is going to set MTBFs for F-16 electrical wiring harnesses! If you are new to the term MTBF, please read this previous blog. If you want more information on why MTBF’s are not set for • Read More >>
Topics: Blog, F-16, F-16 Electrical, F-16 Electrical Wiring Harness, Kapton, Kapton Wire, MTFB, Wiring, Wiring Harnesses
What is Inherent Viscosity for F-16 Wiring Harnesses?
Posted by John Ashour on December 11, 2017
This is the most difficult blog that I have written concerning F-16 wiring harnesses. It is difficult because it is a technical subject that needs to be understandable to the average reader of InterConnect’s articles. InterConnect has written blogs on the benefits of Kapton wiring as well as the problems of Kapton wiring. InterConnect • Read More >>
Topics: Blog, F-16, F-16 Electrical, Kapton, Kapton Wire, Wiring, Wiring Harnesses
What are the Ten Most Problematic Areas for Kapton Wiring Inside an F-16?
Posted by John Ashour on November 13, 2017
Like most airplanes, the F-16 is made up of four basic structures: (1) fuselage, (2) wings, (3) horizontal tail, and (4) vertical tail. Inside each of these structures are smaller sections that house: (a) other structures such as bulkheads, (b) equipment (both electrical and mechanical), (3) tubing/ducting, and (4) electrical wiring harnesses. Tubing/ducting and electrical • Read More >>
