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Spark Plug Cap Assembly Procedure

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Old 09-06-2010, 01:39 PM
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All Day Dan
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Default Spark Plug Cap Assembly Procedure

I did some searches but I did not come up with what I need about the spark plug caps we use. I need an assembly procedure that includes dimensions and photographs that show the assembly procedure of the caps. Are there any out there? Dan
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Old 09-06-2010, 03:15 PM
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Default RE: Spark Plug Cap Assembly Procedure

I've seen it in several places

I'm thinking it is on the RCEXL site too i'll look
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Old 09-06-2010, 08:50 PM
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Default RE: Spark Plug Cap Assembly Procedure

Try here http://www.dlenginesaustralia.com/do...apAssembly.pdf Capt,n

I just typed the question into Google search....works evertime!!!!!!!!!!!!!!!!
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Old 09-06-2010, 09:19 PM
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Default RE: Spark Plug Cap Assembly Procedure

Thank you Captain and Mr. Moderator,
I got the same page of assembly photographs but there were no recommended dimensions. I don't see the connection being made to the electrode spring or cap unless it's built in. Dan.
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Old 09-06-2010, 09:51 PM
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Default RE: Spark Plug Cap Assembly Procedure

Here's another

http://www.justengines.unseen.org/ac...lugcapassy.pdf
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Old 09-06-2010, 09:55 PM
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Default RE: Spark Plug Cap Assembly Procedure

Here's another 1/4-32 type assembly. If you look closely there is a spring inside the insulator that the resistor lead slides into

http://www.rcexl.com/news/Accessories/6.html
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Old 09-06-2010, 09:59 PM
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Default RE: Spark Plug Cap Assembly Procedure

Here's some more assembly pictures

http://www.rcexl.com/news/Accessories/14.html
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Old 09-06-2010, 10:08 PM
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Default RE: Spark Plug Cap Assembly Procedure

http://www.rcuniverse.com/forum/m_95...tm.htm#9513934
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Old 09-06-2010, 10:26 PM
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Default RE: Spark Plug Cap Assembly Procedure

In this picture if you look close you can see the spring inside the insulator boot of this CM6 size installation

[img]{akamaiimageforum}/upfiles/167062/Uq49938.jpg[/img]
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Old 09-06-2010, 11:28 PM
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Default RE: Spark Plug Cap Assembly Procedure

Demensions, which ones and what for? Is it a CM-6 plug cap or a different spark plug?
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Old 09-06-2010, 11:35 PM
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Default RE: Spark Plug Cap Assembly Procedure

Is the resistor lead supposed to penetrate the spring and be grasped by the coils? Or is it supposed to be simply pushed against the spring's coil? The latter sounds like RFI just waiting to happen.


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Old 09-06-2010, 11:41 PM
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Default RE: Spark Plug Cap Assembly Procedure

It is the latter, quite a few thousand units out there happily sparking away without producing any EMI issues.
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Old 09-07-2010, 05:45 AM
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Default RE: Spark Plug Cap Assembly Procedure


ORIGINAL: jedijody

It is the latter, quite a few thousand units out there happily sparking away without producing any EMI issues.


I'm sure the EI unit wouldn't care. My concern is what the radio receiver thinks. As I have explained in other posts, we are dealing with a variable noise floor. Even in the best of conditions it can be forced quite high by extraneous RF sources. The higher the noise floor, the smaller amount of clear signal there is for the receiver to work with - even with spread spectrum technology being employed.

I would feel better if there was a way to solder the two together. One would then need a two piece nylon containment device instead of the one piece device currently used in the photos.


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Old 09-07-2010, 06:37 AM
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Default RE: Spark Plug Cap Assembly Procedure

The existing noise floor seems to be acceptable?

When the cap is properly installed on the correct size spark plug, the wire pig tail is firmly captured within the coils of the spring as they are compressed by the top of the spark plug.
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Old 09-07-2010, 08:11 AM
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Default RE: Spark Plug Cap Assembly Procedure

NM2K,

The wire can be inserted into the spring and be captured by it. That method is used in another type of ignition, similar in design, with no problems. Using that method you must be assured the urethane cap has no breaks that would permit the charge to arc over the inner boot to the outer cap.
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Old 09-07-2010, 09:15 AM
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Default RE: Spark Plug Cap Assembly Procedure

Some time ago Bosch did make a very goo metal shielded spark plug boots. I remember seeing them on small engines years ago! Capt,n
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Old 09-07-2010, 09:35 AM
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Default RE: Spark Plug Cap Assembly Procedure


ORIGINAL: captinjohn

Try here http://www.dlenginesaustralia.com/do...apAssembly.pdf Capt,n

I just typed the question into Google search....works evertime!!!!!!!!!!!!!!!!

thats neat ... i always thought it was more difficult
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Old 09-07-2010, 10:22 AM
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Default RE: Spark Plug Cap Assembly Procedure


ORIGINAL: NM2K


ORIGINAL: jedijody

It is the latter, quite a few thousand units out there happily sparking away without producing any EMI issues.


I'm sure the EI unit wouldn't care. My concern is what the radio receiver thinks. As I have explained in other posts, we are dealing with a variable noise floor. Even in the best of conditions it can be forced quite high by extraneous RF sources. The higher the noise floor, the smaller amount of clear signal there is for the receiver to work with - even with spread spectrum technology being employed.

I would feel better if there was a way to solder the two together. One would then need a two piece nylon containment device instead of the one piece device currently used in the photos.


Ed Cregger
Pretty solid connections there, no arcing or possibility of vibration to cause RFI. Again, there are many thousands of units out there NOT causing any issues whatsoever with any radio system that has been used in the last 20+ years.
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Old 09-07-2010, 06:36 PM
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Default RE: Spark Plug Cap Assembly Procedure

These are all great inputs and just what I was looking for. I am amazed that there was no soldering required. Jody's description from a previous post says it all and his last image, a "cutaway" is perfect. Jody, not to change the subject, but will the RCexel ignitions run with the pick up on the Brisons or do they have to be changed? Dan.
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Old 09-07-2010, 06:42 PM
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Default RE: Spark Plug Cap Assembly Procedure

The connector is different

The CH has a Deans

RCEXL has a JIS like a Futaba, JR, and Hitec
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Old 09-07-2010, 06:52 PM
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Default RE: Spark Plug Cap Assembly Procedure

w8ye, I can live with that as long as I don't have to change the sensor. Hopefully Bill will get back in action soon and save all of us as he usually does. Dan.
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Old 09-07-2010, 07:50 PM
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Default RE: Spark Plug Cap Assembly Procedure

The older Brisons had a mechanical advance coupled to the carb, You don't need that with the RCEXL. You just fasten it in the full advance position for the RCEXL
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Old 09-07-2010, 10:00 PM
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Default RE: Spark Plug Cap Assembly Procedure

Pin outs are the same between the Brison CH and an RC Exl. Just change the plug.
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Old 09-07-2010, 10:18 PM
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Default RE: Spark Plug Cap Assembly Procedure

Thanks you two. If I can't get replacements for my C modules, I'll have to convert over to the ones with electronic advance. Dan.
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Old 09-08-2010, 12:46 AM
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Default RE: Spark Plug Cap Assembly Procedure


ORIGINAL: Tired Old Man

NM2K,

The wire can be inserted into the spring and be captured by it. That method is used in another type of ignition, similar in design, with no problems. Using that method you must be assured the urethane cap has no breaks that would permit the charge to arc over the inner boot to the outer cap.


Yes, which would make a two-piece (split lengthwise) nylon containment boot very difficult, if not impossible, to employ.

T.O.M. Roger on capturing the wire withiin the spring. So what do we home assemblers do? Just live with the arcing that will occur with a simple push fit being employed?

Yes, Jim, there is some merit to your argument that this system has been working successfully for most folks. But it makes me wonder how many planes have been lost when a larger than normal gap occurs by someone pulling the boot end while holding the cable? That solder job is going to allow for some movement. It wouldn't take much to cause a problem. The metal cover will shield the spark somewhat. I'm worried that the gap of the plug combined with the gap in the nylon holding fixture could make the spark to the engine somewhat more unreliable than normal.

I'm an RF tech by trade. I don't like unsoldered, welded or non friction clamped connections.


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