Ivan's RV-7

Fabricating spring clip and installing Power Relay ModulesTimer icon2h

April 11, 2026

A few small tasks for my electrical system.

First, I created stainless steel retaining clips as an additional measure to keep diodes in place. They are already screwed to the copper bar, but I thought the clips would help with better contact, and also act as a secondary retainer. I added little bumps to the copper bar to lock the clips in place.

I put some Burndy Penetrox A between the diodes and the copper bar to improve electrical and thermal conductivity.

The retaining clips

Also, I countersunk the holes for the flush screws that are holding Power Relay Modules. I didn't have a countersink with a large enough pilot, so I just used some brass tubing to make the pilot bigger.

The countersink bushing

Power Relay Modules installed.

The Power Relay Modules

The copper bar is 1/2" wide, and I think it's too narrow -- I will be replacing it with a 3/4" copper bar.