PIGD ring tongue terminals for bus bars, terminal blocks, studs, and circuit breakers

For blue sea bus bars

5-way bus bars with #10-32 studs and #8-32 screws

10- and 20-way bus bars with #1/4" stud and #8-32 screws

MIL-W 22759/16 Tefzel maximum insulation diameters

• 10 AWG - 3.61mm
• 12 AWG - 2.97mm
• 14 AWG - 2.41mm
• 16 AWG - 2.06mm
• 18 AWG - 1.85mm
• 20 AWG - 1.57mm
• 22 AWG - 1.37mm

TE connectivity PIDG ring terminals for smaller wire sizes and screws, compatible with 58433-3 crimper

#8-32 screw options

22-16 AWG

Maximum MIL-W 22759/16 insulation diameter for 16AWG is 2.06mm so 320554 or 320551 are sufficient and preferred, alternatively 31886 or 31890. In fact the 3.18mm max insulation diameter for these types is good for 12 AWG wire (2.97mm max diameter). The 320551 is preferred over the 320554 as the metal part is wider

1-320551-3 | TE Connectivity, PIDG Insulated Ring Terminal, M4 Stud Size 20 AWG 20 AWG Wire Size, Red | RS - 100 units

But from element 14

320551 AMP - TE CONNECTIVITY, Ring Tongue Terminal, M4, #8 | element14 Australia - MOQ 1

TE connectivity PIDG ring terminals for larger wire sizes and studs, compatible with 58433-3 crimper

12-10 AWG

Maximum MIL-W 22759/16 insulation diameter for 12AWG is 2.97mm and 10 AWG is 3.61mm, far below the limits imposed by the PIGD terminals

#10-32 stud options, #1/4" stud options, and 8mm stud options (for grounding stud on firewall)

#10-32 studs can preferably use 324918, 32883 or 36161 due to smaller insulation diameter limit, alternatively 131071 or 35109

The 36161, 131071 or 35109 are preferred due to having more metal

The 36161 is preferred overall, but his is all I can see on the RS webpage

32883 | TE Connectivity, PIDG Insulated Ring Terminal, M5 Stud Size 12 AWG 10 AWG Wire Size, Yellow | RS - 50 units

But I can get from element 14

36161 AMP - TE CONNECTIVITY, Ring Tongue Terminal, M5, #10 | element14 Australia - MOQ 10

1/4" (M6) studs can preferably use 320569 due to smaller insulation diameter limit, alternatively 35110

320569 AMP - TE CONNECTIVITY, Ring Tongue Terminal, M6, 1/4" | element14 Australia - MOQ 1

This is all I can get from RS

2-35110-1 | TE Connectivity, PIDG Insulated Ring Terminal, M6 Stud Size 12 AWG 10 AWG Wire Size, Yellow | RS - 50 units

5/16" (M8) studs can preferably use 320576 due to smaller insulation diameter limit, alternatively 35111 or 160298. 320576 or 35111 are preferred due to having more metal

2-320576-2 | TE Connectivity, PIDG Insulated Ring Terminal, M8 Stud Size 12 AWG 10 AWG Wire Size, Yellow | RS - 10 units

320576 AMP - TE CONNECTIVITY, Ring Tongue Terminal, M8, 5/16" | element14 Australia - MOQ 10

35111 AMP - TE CONNECTIVITY, Ring Tongue Terminal, M8, 5/16" | element14 Australia - MOQ 10

EarthX batteries, or the optional terminal adapters have M6 hex head screws. There will be a need for ~10AWG wire to connect to the battery for the avionics

Placement of firewall electrics - We Build Planes

Canadian Shunt LA-100-100 current shunt has 1/4" studs

Bussmann LMI stackable fuses have M5 studs

Blue Sea 2408 terminal blocks have M3.5 and 7.9mm wide channels

The 36151 is the preferred option, but 36152 is fine. 51863 will also do. 36149 or 36150 are a little too fragile.

51863-1 | TE Connectivity, PIDG Insulated Ring Terminal, M3.5 Stud Size 22 AWG 16 AWG Wire Size, Red | RS - 100 units

This is a pain, only 8 needed

51863-3 AMP - TE CONNECTIVITY, Ring Tongue Terminal, M3.5, #6 | element14 Australia - MOQ 10 which is better

Also

36151 AMP - TE CONNECTIVITY, Ring Tongue Terminal, M3.5, #6 | element14 Australia - MOQ 10

36152. AMP - TE CONNECTIVITY, TERMINAL, RING TONGUE, #6 | element14 Australia - MOQ 1

Klixxon 2TC2 circuit breakers

The MS51957-41 screw has #8-32 thread, max head diameter 0.322" = 8.18mm, so the 320511 with diameter 7.92mm is also ideal

320551 AMP - TE CONNECTIVITY, Ring Tongue Terminal, M4, #8 | element14 Australia - MOQ 1

Element 14 appears to be the best supplier, with lower MOQs and in some cases cheaper. However there are lead times of several days rather than overnight

Summary

36151 AMP - TE CONNECTIVITY, Ring Tongue Terminal, M3.5, #6 | element14 Australia - MOQ 10

320551 AMP - TE CONNECTIVITY, Ring Tongue Terminal, M4, #8 | element14 Australia - MOQ 1

36161 AMP - TE CONNECTIVITY, Ring Tongue Terminal, M5, #10 | element14 Australia - MOQ 10

320569 AMP - TE CONNECTIVITY, Ring Tongue Terminal, M6, 1/4" | element14 Australia - MOQ 1

320576 AMP - TE CONNECTIVITY, Ring Tongue Terminal, M8, 5/16" | element14 Australia - MOQ 10