I have decided to pull the Fuel Load Indicator, off the shelf as its interface is Wire-Wrapped. Wire-Wrapping is winding a silver-plated Kynar wire around a square post, this produces a gas-tight joint, as each 90-degree turn fractures the wire.
The major stumbling block to this is tooling. (not cheap)
- A Wire-Wrap gun
- Wire-Wrap bit and sleeve for the gun.
- Kynar wire
- No-Nik stripper.
- Unwrapping tool
- Wire, etc.
Wire-Wrap is covered in MIL-STD-1130 C which can be found at Every Spec and this document is the Bible.