July 14: I’m disgusted. Having made this cable, and five more like it, I get to make them all again. They are all trash. Can you tell why? Post a comment if you figure it out.
I made my first control cables for my Bede BD-4C last night! Crimping the ends seemed kind of intimidating to me but once I tried it, it was easy. 🙂 Here are pictures and, as always, you can click on them to see larger versions.
This cable is part of the aileron controls for my plane, a Bede BD-4C.
Very cool!!! Did your electric screw driver work or did it take a bunch of turning by hand?
Not much hand wrenching at all.
Im thinking the tail of the cable is too short or the swage isn’t quite right. Sorry Art.
Good guess but nope.
Is it the twist in the cable?
Good guess, David, but that’s not it.
Is this the cable/swage compatability issue? Hard to tell from the photo what type of cable it is.
It is 7×19 stainless steel cable with copper nicopress sleeves. That is all compatible and OK.
Look into that a little further. I ran into an FAA publication requiring plated fittings for stainless cable, copper for galvanized.
I don’t know. They look pretty good to me. Did you maybe have some looseness between the thimble and cable? That could cause the thimble to eventually fall out and new problems to manifest themselves.
How about a clue?
Dave,
Good guess. I was concerned that the cables were not taught but they are OK as is.
Here’s a hint. What you see is well constructed but it cannot be installed in the plane because something vital is missing.
— Art Z.
Hi Art, been watching your progress and really appreciate your post. Looks like some heat shrink tubing would complete your fittings. Thanks EAA H-Hints. Keep up the good work.
Dale
Turnbuckle?
Yes! You win the prize of a useless aileron cable. Where would you like me to mail it? 😛
I’m building a BD-4, stretched 7 inches, Continental 0-470 engine, composite skin to alleviate some of the boxiness, my blog (SOMEWHAT OUT OF DATE!) is “building-the-bdfour.blogspot.com”
I made 2 sets of control cables too, by the way, but for different reasons. Heck, I’ve made 2 sets of LOTS of things; it seems to be the way it works for lots of builders.
Remember to enjoy the build!