The $900 harness I built got flagged for 3 minor pin issues. Overkill or am I missing something?
Last month at a regional shop near Dayton, I finished a full cockpit harness rewire on a 1968 Cherokee, about 14 hours of work and $900 in materials. The IA who signed it off flagged three pins that were 0.002 inch under spec on the cannon plug, said it needed a full re-pin. I checked my crimp tool calibration and measured again, they were within the mil-spec tolerance band, just not in the middle. He flat out said "close enough isn't airworthy" and made me redo all 37 pins. Three years ago I would have just done it and moved on, but now I'm wondering if we're chasing prints instead of function. I get that a loose pin can vibrate out over time, but 2 thousandths? Has anyone else pushed back on a sign-off like this and won, or is this a hill I should just let go?
Did you check if that IA has a personal stake in the local parts shop or a buddy who sells pre-terminated harnesses? I've seen guys get real picky when their side hustle depends on failing others' work. Also, his logbook signoff is his name on the line, so 2 thousandths might be his way of covering his own butt, not yours. Next time, ask him to show you the exact mil-spec page he's using and watch how fast he changes the subject. If he's got a reason, fine, but if it's just pride, that's on him, not your crimper.