Brief Description: Determing Control Cable Lengths & Routings
Started the day by completing the panel frame clips by drilling the clips for nut plate rivets, countersinking, and riveting the 2 nut plates onto each clip.
Installed the hardware for routing and connecting the control cables firewall forward. In this process, found that there is a control cable bracket that must be installed between the throttle body and the engine. Removed the throttle body from the engine, which damaged the throttle body gasket. Cleaned up both surfaces for a new gasket, and checked a local auto parts store for a gasket during lunch - they didn't have anything to match the one provided by Van's with the cable bracket. Looked up the gasket part number in the Lycoming parts manual and ordered 4 gaskets from Aircraft Spruce.
Temporarily installed the throttle body with the control cable bracket to the engine with single nuts finger tight. Installed the cable bearing connectors to the control arms for the throttle, mixture, and prop governor. Had to move the bearing from the inside to the outside of the governor arm as it interfered with the governor arm stop. Installed the cable cushion clamps to the engine mount for the cables per the Van's drawings.
Routed weed-eater line from the throttle and mixture arms to the throttle quadrant to use for cable measurements..Attached the quadrant ends to the quadrant arms using electric crimp on rings and 8R8 screws.
Determined a suitable routing for the prop governor cable over the top of the engine since the Van's standard lower routing won't work with the AC compressor under the governor. Drilled a 1/4" hole through the back baffle in a suitable location. Will enlarge this hole as necessary once the actual cables are in hand. Determined that 2 cushion clamps will likely be required to route the prop cable from the back baffle to the firewall box with holes for the cables entry into the fuselage. Installed these cushion clamps. Ran weed-eater line from the governor to the quadrant.
