I reconfigured my vacuum apparatus to conform with the layout you sent in the pic. The vacuum pump does a nice job of holding a vacuum. Unfortunately, the enclosures still don’t hold a vacuum. Wherever the leak is, it’s not small. I can’t pump the handle fast enough to get past 1 or 2 in hg. on the pump gauge.
I pulled the battery enclosure out and checked all the penetrators on the bulkhead for orings. They are all there and clean. I’m almost certain the penetrators on the electronics enclosure are the same, but removing them at this point for inspection will require several hours of work.
I tried connecting one of the vacuum plugs to the battery enclosure and plugged the other with the rubber stopper. Same result - no vacuum. I’m guessing the issue might be in the power cable connecting the electronics enclosure to the battery enclosure? The power wires on both ends appear to be well potted. I guess I could remove the battery cable penetrator from the battery enclosure and replace it with a plug penetrator from the electronics enclosure bulkhead and see if I can pull a vacuum on the battery enclosure with no battery cable. That way at least I’d know the problem is in the electronics enclosure.
I hate to disassemble the electronics bulkhead. All my wires in the enclosure itself are groomed as well as the cables to the thrusters and lights. Ugh. They look so tidy at the moment. Hate to think about snipping all those zip ties.
This problem highlighted a potential improvement in the documentation. It might be helpful to insert a vacuum test at some point into the assembly manual. Perhaps move the section where the thruster and light penetrators are installed into the bulkhead to precede the actual connection of all the wiring to the boards in the enclosure. That way, you could do a vacuum test by simply stuffing all the unconnected wires into the enclosure and doing a vacuum test at that point - before all the connecting and grooming occurs. It would be relatively simple to diagnose a problem at that point. It’s a thought.
Any ideas for me at this point before I start snipping…?