Brief Description: Rudder cable and other problems
Spent the day addressing some minor problem areas.
Temporarily re-installed the horizontal and vertical stabilizers to review the rudder cable and elevator pushrod rubbing issue. Even after moving the right side cable pulleys outboard IAW C01-Rev B, there was still slight rubbing of the rod and cable between frames 2 and 3. I made a new pulley assembly and installed it inboard of the pushrod hole on the right side of frame #3. The routing of the cable is now inboard of the pushrod and there is about 3/8" clearance between the rod and cable. There is still some cable rubbing at the exit of the aft skin, so more hole work is needed there.
On the lap belt attachment point, the specified 3/8" bolt head would interfere with the side skin since there is only a 0.125" space between the bracket and the skin and the bolt head is about 0.23" thick. I reduced the specified 1/2"ODx3/8"ID bushing by inserting an additional 3/8"ODx1/4"ID bushing to use a 1/4" bolt. The scale in image 1 shows the projection inside of the skin line. I'll need a very thin wrench to change the belts when required.
When checking the elevator travel, there was some interference between the elevator cross tube and the rudder post skin when the elevator was full up. Trimmed the skin for clearance. There appears to be some additional interference between the center upper rudder post bolt and the elevator horn weldment. The upper back part of the welded flange hits the center bolt before the elevator stop on the bottom of the horn touches the rudder post. This might be resolved with some minor grinding in the offending area.
Will also need to trim some of the forward rubber skin since it interferes with the top of bulkhead #4. There needs to be at least a little gap for the turtledeck to fit.
