More Ignition Woes

My Jeff Rose ElectroAir electronic ignition quit working after 4.5 hours of flight time. I discovered it shortly after start-up one day, as the tach read zero. My tach input is supplied by the EI. Jeff checked out the ignition and sent me a new pick-up for the right magneto hole. I was back in business. Two weeks later, I have 12.5 hours on the plane, and I am cruising past Pilot Mountain at 3,500 feet. I am literally thinking about how the engine has been running well, when suddenly it misses. Surely that was my imagination. No, there is again (Pucker). OK, nearest button, N63 is 5.4 miles that way, right turn.

At first I didn't know what it was. All temps and pressures were normal (except for the pilot), but when it missed it was real obvious. My initial thought was the prop was loose or the engine was about to jettison a cylinder. Not cool. I orbited N63 for two laps at a reduced power setting and it seemed to improve. Then I noticed the tach jumping around each time it missed; 2500, 2350, 800, 2500 RPM. Based on this I decided the EI was intermittent. With half an electronic ignition and one mag, I decided to head for home while climbing gently and keeping alternate landing sites in mind. I made it back to 8A7 with no additional trouble. A quick mag check on the ground showed normal.

After calling Jeff the following day, I checked the pick-up with the multimeter. He said the red and black wires should give 600-800 mOhms resistance. They did, until I started moving the wires around. One of them was frayed internally. Although I thought I had plenty of slack in the cable, something fatigued the wires or they were weak from the start. As harsh as the environment is ahead of the firewall, you'd think some stout wires would be in order. Anyway, the pick-up is enroute to ElectroAir for repairs and I am grounded again.

[Note: Jeff is no longer selling ignitions because his supplier cut him off. He continues to provide exceptional support to his existing customers.]

Update: Within a fews days I had the repaired pick-up back. I installed it just in time to leave leave town on business (on a commercial flight). A test run proved things were working well, but lousy weather has kept me on the ground.

Update II: The weather has finally lifted a little, and two flights have proven that the ignition is running strong. Hope it stays that way!!

The expected 600-800 mOhms...

...but when I move the wire coming out of the pick-up 1/4" with the tip of my finger, the meter goes to zero. Indicating the wire has become fatigued and broken.