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Kupe's Zodiac 650B
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Date:  4-22-2019
Number of Hours:  2.00
Manual Reference:  
Brief Description:  Final Installation of Aileron Cables: 1

Spent the day reattaching all the aileron cables in preparation for final rigging. You may recall from previous complaining that the aileron cables are quite a challenge to access. During Winter, I ignored the aileron cabling the few days I was able to work in the hangar while I mulled over how I might fix my deflection problems. Today, I spent my time loosely reattaching the cable turnbuckles then locking all the controls into place. This involved multiple tasks.

First, I disconnected the control stick in the front so I could push it back far enough to access the bolts that attached the cables to the control stick (see verticle gray tab in Image 1). The nuts for these bolts are cottered into place, a task I couldn't complete with the contoll stick fully installed. After securing and cottering the bolts, I reinstalled the stick.

Next, I clamped each aileron to its neighboring flap to establish the ailerons' neutral position, then froze the stick in place using a combination of 2x4s and bungee cords.

Next, I worked on setting the final length of the left and right aileron cables (this was previously accomplished for the balanced cable) by assembing each cable loop through the turnbuckle around a thimble and secured a nicopress sleeve in place on each cable using cable clamps. Lastly, I reassembled all the turnbuckles in order to test the installation.

The upgraded bellcrank had done the trick - the ailerons now have full authority.
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Picture from Sep 2018 showing the connections of the aileron cables (horizontal ones).

Picture from Sep 2018 showing the connections of the aileron cables (horizontal ones).

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