Rudder Cables - Part 2

Normally in these blogs reference to any additional information is at the end. With the task of preparing the cables and lock wiring the following article's were read and viewed before beginning.

The Big Squeeze

Video on Lock wiring Turnbuckle

Cutting Cable

Swagging Cables

My Big Squeeze

The goal

The manufacturer of the Swage-It tool recommends two [2] ferrules be used at each termination. A length of 1/8'' cable 4500 mm long was prepared at both ends applying one wrap of masking tap to allow it to fit through the ferrules.

The Swage-It tool will only work correctly with copper Nico Press ferrules, installed in accordance with instructions supplied with the tool using either plated or natural depending on cable type.

NO EXCEPTIONS......!



Rudder End
The initial assembly is covered in the article from kit planes and EAA video. 

After placing the ferrule against the thimble the Swage-It was fitted about the center of the ferrule and nipped up until it grips the cable lightly - once final adjustments were made, tension was maintained by pulling the cables and then using a series of 1/4 turns both bolts were tightened until they bottom out evenly

The Swage-It tool was re-positioned so the crimping jaw aligned with the outer edge of the ferrule, crimped then repeated at the rear. Positioned the second ferrule then crimped it using the same procedure.

Test crimp with Swage-It
Refer sample photo above

The waste was trimmed back using a cold chisel with a block of steel, I chose to leave about 15 mm for fear on nicking a cable. The standards state that the minimum tail is one diameter. 

The exposed tail was wrapped with self bonding buytal rubber tape to prevent unwanted installer blood loss and associated pain.

The crimps were visually inspected and checked using a go-no gauge on both sides at each crimp, next the cable was threaded through the fuselage, pulleys and nylon guides. 

Then at the rear secured using temporary AN3 bolt's to the rudder horn. 

Note: Due to the larger profile of the copper ferrules the opening through the tail had to be enlarged as they caught on the factory opening which was designed to accommodate the smaller steel ferrules.

Cockpit Assembly
The rudder was locked using two lengths of 75 x 25 mm DAR pine clamped to the fuselage sides then chocked using two piece's of packing foam fitted between the timber and the rudder skins. A length of aluminium angle was placed along the side of the fuselage using the top row of rivets as a datum. The distance to the edge of the rudder checked at both sides with the foam blocks moved in and out to adjust the position until both measurements are equal.

The front pedals were located using the firewall as the datum so it is critical that the connecting rods are the same length to proceed.


Basic Guidelines
"Safety all turnbuckles with safety wire using either the double or single wrap method, or any appropriately approved special safetying device complying with the requirements of FAA Technical Standard Order TSO-C21. The swagged and un-swagged turnbuckle assemblies are covered by AN Standard Drawings. Do not ever reuse safety wire. Adjust the turnbuckle to the correct cable tension so that no more than three threads are exposed on either side of the turnbuckle barrel. Do not lubricate turnbuckles."

Refer video for details

A&P Rigging Chart 
Ambient of 85 deg F [29 deg C]

Rudder Pedals
Assembled the cable loosely with a loop formed at the end with both ferrules installed onto the cable, fitted the thimble and the loose end of the wire through the first ferrule. 

Adjusted the length until the face of the thimble was in line with center of the mounting hole in the turnbuckle while applying as much tension as practical by hand, wrapped masking tape at the rear of the ferrule. 

Fitted the Swage-It as described previously and slid the ferrule up against the thimble and lightly clamped the ferrule. This operation was repeated a number of time to ensure NO slack was in the cable and to adjust the position of the thimble and when happy crimped the ferrule.

The second ferrule was placed about 50 mm [2''] from the first, crimped with the tail finished as described previously.

Cockpit Rudder Connection

Comment
The cables will be tensioned and lock-wired in a later blog once the fuselage has been displayed at AUSFly in September and will be written up at that time.