Building tips and hints

[jtpitkin06]

Making Rudder Cables –( Model 7 with foot wells.)

The Kitfox does not use turnbuckles for matching the rudder cable lengths. If a thimble is swaged on a rudder cable out of position, one pedal will be ahead of the other when the rudder is neutral. Here is how to get them perfectly aligned.

When you are ready to swage the thimbles on the rudder cables, clamp everything in position. Clamp a board across the forward fuselage to hold the rudder pedals even with the firewall. The foot pedal springs should be installed on the adjuster pulleys to keep tension on the assembly. Clamp another board and shims to hold the rudder in line with the vertical stab.

Plan on swaging the full length master cables first. When the master cables are taut, you can follow with the co-pilot spliced cables.

Take up any slack in one cable and clamp it just aft of a fairlead near the rudder. A quick clamp or vise grips work well. [refer to picture 1]

Now to crimp the thimbles. Hold a thimble between the rudder horn links and insert a bolt through the links and thimble. No need to attach a nut as you will remove it in a few minutes. Pass the cable through a Nicopress sleeve, then around a thimble, then back through the Nicopress sleeve. Take up any slack in the cable. Next make an index mark on the cable and the loose end next to each other. Use a red felt pen for marking. Black on stainless cables is hard to see. [ refer to picture 2]

Now remove the thimble bolt. The cable will be easier to swage without having to hold all of the pieces in tension. Line up your index marks and slide the Nicopress sleeve as close to the thimble as you can. This ensures the thimble stays captive on the cable. Slide your Nicopress tool onto the sleeve. Just before you compress the sleeve, double check the index marks. [refer to picture 3]

If you mark things carefully you can get the rudders matched within 1/8 inch.

When you do the co-pilot cables, attach the full length cables to the rudder to keep tension on the cables. Once again, use a red pen to make reference marks.

John Pitkin