The plans call for 2" pulleys for the aileron cables and what I have on hand are 2-1/2" ones which I will stick with. The rear gear fittings were all drilled with 1/4" holes per the plans, however the pulleys need 3/16" so I welded over the old holes and drilled new ones just for the pulleys. Each pulley has a cable guard so I have made the first out of .035" 4130N which had be be drilled precisely to avoid rubbing or having too much gap that the cable could roll off the pulley itself. To be sure the guard wasn't going to rotate when tightened up, I welded it to the gear fitting. Happy with the result, I will be doing the others the same way.
