Re: Cables
(I know this is not how some will tell you how to do it),
Well Crash, you asked for it. The correct (and not to mention legal) way to make a thimble eye splice is to make the center compression first, the one next to the thimble next, and the one farthest from the thimble last. This is because the sleeve grows a lot in length when it is compressed. A correctly crimped 1/8" sleeve should grow from 9/16" to 3/4" for example. By crimping the ends first, this normal expansion is not allowed, and the strength of the first two crimps,or the cable itself could be compromised.
I bend the 4 sharp points of the thimble together a little so that initially they fit inside the sleeve a little. When the center of the sleeve is compressed, the sleeve expands up the thimble. When the thimble end is then compressed, it captures all the points and tightens the cable around the thimble, keeping everything tight and neat. The end of the cable is trimmed to the proper length, and the end crimp made. I can't see any advantage to doing it any other way.
On a rebuild, when all the repairs and mods are done, and everything is ready for cover, I'll completely assemble the airframe and rig the plane. Then I will make up the cables like Crash discribes. Without cover on, it is easy to check pulley and guide alignments, correct movements, etc, and correct anything that is out of line.
Inspecting older aircraft, a very common thing I find is badly, or incorrectly made cables. If you don't make a lot of cables, and you try making a set, you will probably screw up a few times. If you don't get it right, take the cable out and try again. Cable is cheap, and this is not a place to scrimp. Legally, newly made cables should have three threads exposed max, or four threads max in the turnbuckles when correctly tensioned. Get it right, or keep trying till you get it right.
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