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Kupe's Zodiac 650B
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Date:  8-21-2013
Number of Hours:  2.00
Manual Reference:  6-W-10
Brief Description:  Aileron Cables

Received steel cable cutters in the mail yesterday - amazing how important the proper tool can be. This morning I headed to the basement to swage loops into the two aileron cables. Swaging involves threading the steel cable through a nicopress collar, then looping the end of the cable back through the nicopress collar. To maintain the loop's shape, a thimble is placed into the inside of the loop. Once all this is assembled and pulled together snugly (think of a bolo string tie), the nicopress collar is placed into a swager. The purpose of the swager is to compress the nicopress collar tightly around the two pieces of cable to make the loop permanent, or spliced. Swaging is done twice on each nicopress (essentially on each end). The final resut, as shown in image 2 below, is a permanently spliced loop in the steel cable used to attach it to the bellcrank inside the wing.

Once both cables were looped, spliced, cut to length and heat-shrinked on each end (to avoid gettig stabbled by wire ends!), I connected them to the bellcrank which is located on the 7th rib inside the left wing.
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A cable, a nicopress, and a thimble walked into a bar...

A cable, a nicopress, and a thimble walked into a bar...

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Fully swaged and thimbled cable loop all finished. Swaging tool sits next to it.

Fully swaged and thimbled cable loop all finished. Swaging tool sits next to it.

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Aileron cables installed onto the bellcrank and run through the lightening holes to the root.

Aileron cables installed onto the bellcrank and run through the lightening holes to the root.

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