Rudder Pulleys - Part 1

Guides:
There are four bushes to be installed at bulkhead nine [9] and ten [10]. The holes are pre drilled in the bulkheads but not in the bushes. Each bush was matched drilled from the hole with the best  access.

Insert bush mark the first hole with a 1/8'' drill, remove and drill through. 

Re install with a cleco and match mark the other [2] holes, remove and drill through.  

Repeat this operation for the other three bushes and install using 3 pop rivets. This builder chose to install the bushes with their flanges facing each other at the last bay - why? - if you ever need access only one skin has to be removed.

Pulleys:
There are four [4] pulleys to be installed at the spar area, again all holes are pre-drilled.

Inspection off the pulleys revealed that some of the clearances are a little tight for this builders personal preferences. The pulleys were dissembled and fiber washers installed on each side of the pulley to limit the travel of the pulley on the bush. 

The fiber washers were manufactured from 1/4''  fiber  washers enlarged with the taper drill by hand. These had to be held with a cloth as it just plain hurts bare fingers. One step is drilled, reverse the washer and enlarge to 5/16'' to clean up the burrs.

The factory M4 x 20 screw were replaced with 22 mm long screws cut from longer screws to provide two [2] threads projecting from the nylock nut. The tangs were flared by five [5] degrees and pulled into alignment with the screw at assembly.

There are left and right hand version at assembly that allow the pulleys too be installed heads up on both sides

Install as shown in the manual