Field Notes

Avionics Bay Design: Sleds, Switches, Batteries, and Wiring That Survive Boost

How to lay out a dual-deploy ebay that an RSO will arm: sealed bulkheads, a sled that does not eject its battery, and charge wiring.

By Burn Wire

A dual-deploy avionics bay is a small pressure vessel, a switch panel, and a wiring harness that has to survive more acceleration than a dropped phone. Most “altimeter problems” I have watched at the range were bay problems: a 9V that walked out of a clip, a screw switch that backed open at rail exit, a bulkhead that leaked the drogue charge into the computer, or two charge wells that shared a path.

This is the build guide. The flight sequence is in the free dual-deployment article. Charge mass is in black-powder sizing. Pins and vents are in shear pins and vents. Pick the altimeter from the L1 altimeter guide or the Quasar vs Blue Raven comparison, then build the bay to that manual.

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Behind the perforation

  1. The structural recipe
  2. Bulkheads that actually seal
  3. Sled materials
  4. Batteries
  5. Switches
  6. Wiring
  7. Charge wells and the bay
  8. Static ports
  9. Arming procedure that does not scare the RSO
  10. Failure modes worth designing against
  11. Hardware list for a first 3-inch ebay
  12. Bench checks before you pack powder
  13. Explaining the bay to a cert official
  14. Field checklist

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Avionics Bay Design: Sleds, Switches, and Wiring | Burn Wire