This weekend I built the new 3/32" control cables for the rudder pedals. I decided to move them about 3 inches forward so that I could get my knees down to a comfortable level. It took over an hour just to make the cables because all I have is a manual swaging tool. I cannot order the cables pre-made because the end fittings are too large to fit through the guide holes. I tested these cables with a "go no-go" gauge and all 4 ends passed.
Moving the control stick to the center of the glider has been challenging. I have made several McMaster-Carr orders (linear and rotary bearings/bushings) and subsequently returned the items as I am just not satisfied with the products for this application. I had originally though about doing a linear forward/backward control for elevator and rotary (side to side) motion for aileron. I have once again changed my thought process and opted to use a 1/4" swivel bearing for the control stick. I will attach that to a push-pull control cable (3.5" of max travel) and route them back to the aileron and elevator controls. More than likely I will remove some of the hardware in Picture 2 and fabricate an assembly to interface the cables.
The new batteries (LiFePO4) arrived, but they are too long for the 8" aluminum tube (5" OD, 4-7/8" ID). I searched online for almost 2 hours to find 1 company (Columbia River Mandrel Bending) that supplies these tubes in small quantities. I will replace the 8" tube with a 12" tube. The batteries serve as the aft-ballast needed to meet the W&B requirements. The two batteries weigh 4.5 pounds total and provide 12V at 12Ah (144-Wh) of power. This is just over twice what is necessary for a 20 minute engine burn and a 1 hour flight. I can get 2 flights in before a recharge.
