On Aug 8th of last year my next step of wing assembly was to route the aileron cable. I got a wild hair and changed course of action and started the flaps instead. Part of my thinking was it might be helpful to have the flaps set up to determine the clearance necessary for the aileron cable to clear the flap push rod. Now that I have those parts available I can see that it isn't necessary.
I actually spent a good deal head scratching on this. I even made a cardboard mock-up of the flap system to visualize how much the pushrod angled down for deployment so I could figure positioning. When it all came down to it the best thing to do is to position the pushrod in the most extreme position (arms perpendicular to the bottom and pushrod push tight up to the top of clearance hole) and clear that.
There isn't much info out there as to the best steps to setting up the aileron cable other than it needs to have a fairlead to clear the flap pushrod. A while back Glenn Patterson, another Bearhawk builder, offered me his process for setting up the aileron cable. I followed his plan and it worked perfectly. I mounted the fairlead on rib # 5 and did not have to trim any of my .025 ribs.
Here is a condensed version of how to locate the aileron cable holes. (Note: Mounting the fairlead on the heavy rib at 5 will avoid notching any of the lighter ribs.)
Mark the center of the fairlead at No.1 Rib with the point of the ¾” forstner bit using the fair lead tube as a guide.
Measure from the seam of the double rib #1 to the rib face of rib 2, 3, 4 & 5 and write them down. Use the square end of the work table as 1 and then mark the rib spacing down the edge of the table. At each rib draw a square line about 6 inches long to represent the rib. The edge of the table represents the top of the spar web.
