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Falcon XP Build Site (Claude)
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Date: 2-7-2011
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Number of Hours: 0.50
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Manual Reference: B-5.5
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Brief Description: Rudder Pedal Cable Attachment - Safety Issue
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The cable for the rudders attach to horns mounted on the side of the front rudder cables. Per the instructions, the cable fits over a small aluminum spacer that's over a bolt that connects to the rudder horn. The instructions do not say anything about using a cable thimble, but, as I stated in a previous entry, without a cable thimble the cable will wear much faster and will not be able to reach its' design strength; so I will be using a thimble.
The first picture shows a thimble over the bolt and spacer. Except for the addition of the thimble, this is as designed. However, as you can see, the thimble is not much smaller than the nut on the right. It sure looks to me like it would be possible for the cable to slip off the bolt, and, I'm sure, and the worst possible moment.
The second picture shows the modification. A simple change of adding a large washer between the thimble and nut should ensure that the cable is secure and safe. The other change required here, is the decrease the size of the spacer by enough to compensate for the width of the washer. Per AC 43.13-1B, Page 7-11, paragraph 7-64f regarding the use of "fiber or nylon locknuts": "After the nut has been tightened, make sure the bolt or stud has at least one thread showing past the nut." I used my metal mini-lathe to decrease the length of the space by about 1/16" or so.
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Rudder Cable Attachment as Designed
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Rudder Cable Attachment Modified
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