New Horizons, being a 145 FAA repair station and ignition harnesses/ignition leads being our only focus; from WWII radial engine harnesses, to corporate engines, and lastly to today’s new jet engines used worldwide, we have a pretty good idea of the best materials to use and why they are used. Our system is user friendly. The materials used would be the same quality of those used in the jet engine ignition application and backed with the attitude of keeping our customers happy with full on support.
The first area we worked on was the mag plates, making all series screw-in friendly. This concept was tried in the industry before but failed because the sealing grommet was replaced with a cig grommet to allow for a screw in lead that could be removed and replaced without a tear-down of the swedge application. The problem was the air gap around the cig grommet and the mag block caused miss firing at high altitudes. We kept the same concept of the cigarette grommet so the leads could be removed from the block, but we redesigned the original sealing grommet to slip over the cigarette grommet thus removing the air gap. When a lead or leads needs to be removed, just slip off the high altitude grommet, unscrew the lead from the mag plate, remove lead and install new lead and place high altitude grommet and you’re flying again.
Next, you have a choice of BLUE, GOLD, or PLAIN ALUMINUM plug nuts. Also, with customer's choice, 416 Stainless Steel mag plate nut and plug nuts can be used. In the jet engine ignition system, 416 SS is used for it’s non-gulling application and it’s corrosion resistance. Also, it being a magnetic material, the Corona Effect of the ignition is directed to a positive/negative flow from mag to plug limiting air discharge.
Next is our Rigid Elbow. A 90 degree elbow cut down for a sleek tuck-in application. Cut at a 8 degree angle, the 90 degree radius can be made to fit the mounting ferrule lower and have more clearance than competitors elbows. Also, with the screw in plate, Rigid Elbows can be clocked correctly toward the engine eliminating wire strain if the lead was swedged in the wrong direction.
Next is our Flexible Elbow, which comes in a 90 degree bend. The customer can change the 90 degree to a 70 degree or 110 degree bend, or divert it to a position of their choosing. This elbow was created for helicopter engine use. It was for a helicopter mechanic tired of burnt and chaffed wires.