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Date: Tue, 18 Apr 2006 12:26:44 -0400
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From: "F. Barry Knotts" <bknotts@buckeye-express.com>
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Subject: Re: [LML] LIV - Rudder Cable Housings
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Nicholas Paczkowski wrote:
>
> I am about to install the nylon housing (tubing) for the rudder cables ...
>
I just did the same job.  Just some thoughts:

The manual is not terribly useful.  I used it mainly to determine the 
forward starting place for the housing attach point.

I carefully warmed the nylon housing in the kitchen oven set to 200 
degrees.  (The nylon tubing is printed with a notice - "Max working 
temperature - 212 degrees.")  It came out very warm to the touch, but 
able to be handled.  I then shaped it with my hands to straighten it out 
before it cooled.  You only have a couple of minutes...unless you crawl 
in the oven.  I needed to repeat the warming a couple of times on one 
section to get it right.

I then marked with a silver Sharpie on the outside of the fuselage the 
measured fore and aft height of the ends of the cable.  I used a laser 
line projector set up outside the fuselage to connect the two points.  I 
marked the outside of the fuse along the laser line.  Then removed the 
laser and transferred the outside line to the inside of the fuselage 
simply by measuring down the outside of the fuse to the laser 
established line and transfered the measurement to the inside of the 
fuse.  This established a very straight shot front to back.  But be 
aware - you can curve the line upwards by shooting the laser line from 
above the level of the cable run due to the outward curve of the 
fuselage.  Or vise-versa.

I tried this same procedure with the laser line projector inside the 
fuse and got essentially the same result with a lot more work as the 
entire length could not be shot at one time (bulkheads, etc. blocking 
the beam). 

BTW I've found the laser line projector from Home Depot to be 
invaluable.  The model I have is:  Stanley Fat-Max CL2 "Cross Line 
Level."  I used it in the "non-leveling" mode so I wouldn't need to 
adjust the fuse, just the projector.  I'm sure any similar product would 
do the job.

I found that on the left side of the fuselage I needed to fudge the 
midpoint of the line for the cable upward about 3/8 inch because of 
interference with the previously placed aileron control box.

I drilled the holes through all the bulkheads, then finished them with a 
micro hand grinder to make them as close to the sidewall of the fuse as 
possible.

I tacked the housing along its route with superglue while I had the 
cable in the housing and attached at the front and weighted at the rear 
to keep the housing straight.  Careful here to not cause sharp bends at 
each bulkhead pass through.

I covered the entire run with 1 bid.

I also have put the turnbuckles at the back attached to the internal 
bellcrank and the swagged on end of the cable attached to the rudder 
pedals at the front.

Hope this helps you.  My setup seems to have worked well...but, I'm 
still building, so only time will tell.  If you would like pictures, I 
could provide them.  If there are any questions, feel free.

Barry Knotts
LIV-P, Conti TSIO-550 / Building, Perrysburg, Ohio
bknotts884@earthlink.net