I had already run the cable to the carb heat and air filter box, but I didn’t have the final connection completed. Tom offered to machine a few control stops for me, and gave them to me at Oshkosh. I had to refine the routing or the cables a bit, but his parts worked great and I completed the connection.
First however, I needed to shorten the long housing and cable. This was much easier than expected once I was able to determine how long I needed for the travel of the flap and the final cable routing through the frame from the actuation lever under the pilot’s collective. The trick is cutting the cable housing significantly shorter than the control wire itself. To perform this, you need to extend the lever in the cabin as carefully as possible so as to not pull it out past the control lock bearings. You don’t want those coming out and having to chase them all over a dirty shop floor. The best way I found was to have your fingers pinching the bottom of the lever as you slowing remove the lever. Once you feel the bearings in your pitched fingers, stop pulling on the lever and put it back in about a ¼”. Now you can cut through both the cable and the housing back at the carb heat box. Once you clean up the end of the housing, you can push the length of cable back though and connect.
