A Practical Guide for Aviation Maintenance Professionals

In aircraft maintenance and manufacturing, electrical bonding is not just a best practice—it is a regulatory requirement. The Federal Aviation Administration (FAA) mandates that aircraft electrical systems be designed and maintained to minimize the hazards of static discharge, lightning strikes, and electrical shock . At the heart of compliant bonding is proper surface preparation, and that is where pilot bonding brushes play a critical role.

This guide explains how to use pilot bonding brushes to meet FAA electrical bonding standards, with references to key regulations and best practices.

At Shanghai Longguang Industrial Brush , we manufacture stainless steel end brushes and pilot bonding brushes suitable for aerospace bonding applications. Our industrial brush manufacturer capabilities support FAA-compliant surface preparation.

Note: Longguang is a manufacturer and exporter only. We do not provide local installation services.

1. Understanding FAA Electrical Bonding Requirements

The Regulatory Framework

The primary FAA regulations governing electrical bonding include:

Key Bonding Requirements from AC 43.13-1B

2. Why Surface Preparation Is Critical

The Bonding Connection Requirement

To ensure a low-resistance connection, nonconducting finishes, such as paint and anodizing films, must be removed from the attachment surface to be contacted by the bonding terminal . This is where pilot bonding brushes are essential.

What the Brush Does

Pilot bonding brushes are specifically designed to:

• Remove insulating layers (paint, primer, anodization, corrosion) from the annular area around holes

• Expose bare, bright metal for direct metal-to-metal contact

• Protect internal surfaces (threads, mating surfaces) from accidental damage

The Compliance Link

Using the correct brush directly supports FAA compliance by:

• Ensuring the removal of nonconductive finishes as required by Par 11-189(a)

• Providing a clean surface for bonding connections

• Preventing corrosion by enabling proper post-finishing

3. How to Use Pilot Bonding Brushes for FAA Compliance

Step 1: Select the Correct Pilot Diameter

The pilot pin must exactly match the hole diameter to ensure proper centering and surface contact.

Step 2: Prepare the Surface

Use the brush to remove all nonconductive finishes from the bonding area. The pilot pin protects internal hole surfaces from accidental damage.

Step 3: Apply Post-Finish Protection

Per AC 43.13-1B, a protective finish should be applied to the completed connection within 24 hours to prevent corrosion .

Step 4: Verify the Bond

Measure resistance to confirm it meets the required standard (0.003 ohm or less) .

4. Corrosion Prevention – A Critical Compliance Factor

One of the more frequent causes of failures in electrical system bonding and grounding is corrosion . Aircraft operating near salt water are particularly vulnerable.

FAA-Approved Practices

How Pilot Bonding Brushes Help

By enabling precise cleaning of only the bonding area, pilot bonding brushes allow proper post-finishing to be applied, preventing corrosion and ensuring long-term bond integrity.

5. Longguang's FAA-Compliant Brushing Solutions

Why Choose Longguang?

For more information, please visit:

• End Brush Series

• Why Choose Longguang

Conclusion

Meeting FAA electrical bonding standards requires proper surface preparation—and that means using the right tool for the job. Pilot bonding brushes are specifically designed to remove insulating coatings from bonding areas without damaging critical surfaces. When combined with proper post-finishing and resistance verification, they help ensure compliance with AC 43.13-1B and § 25.899.

Quick Compliance Checklist

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