Today I worked to install the lower pulley assembly and route the cables up through the forward post on the left side. As you can see in the photo, I mounted the pulley temporarily on the outside to draw a line for where the cable would pass through the horizontal and vertical assemblies. Next, I made the doubler for the lower pulley assembly per the plans, and then installed with one cleco until I could run the cable up through the post assembly to check for alignment. On all the horizontal pieces, I simply drilled a 1/2" hole with a step drill bit. On the vertical where it enters the post from below, I drilled two holes and cut out in between with a dremel cut off wheel.
In addition, I split the inside post skin per the plans and made a doubler for an inspection cover. I also flush riveted a gusset in place, see the uppoer part of photo 3. The pulley is hidden behind that gusset.
