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Tried safety wire on a fuel line with .032 instead of .025 and the inspector caught it in 10 minutes
I've been doing safety wire for 6 years at a shop in Bakersfield and figured I knew what I was doing. Grabbed the .032 spool off the cart last week out of habit because it was closest, twisted up a fuel line fitting on a Cessna, stepped back proud of my pigtail. Inspector walks over, looks at it for maybe 10 seconds, and says "that's not gonna pass, too thick for that fitting." He was right. Pulled the spec and .041 and .032 are for bigger hardware, not what I was on. Had to cut it and redo the whole thing. What got me is nobody ever told me why the sizes matter, just handed me a spool on day one. Any of you have a wire size cheat sheet you actually trust, or do you just go by feel after a while?
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