control cable questions

[Dick[_1_]]

Having to reject the last nicropress
on the rudder, two strands were cut when the nircopress was cut off with a
drmel tool.

The question is whether we can reinstall a nicropress in the original
position and then add one an 1/8" further?? or,

Make splice two lengths of control cable with double nicropresses?? or,


Is there any reason why a turnbuckle couldn't be used ouitside the fuselage
at the rudder??

Thanks

[Tim Ward[_1_]]

"Dick" > wrote in message
news:g06Uj.5548$0L.5089@trnddc07...
> Having to reject the last nicropress
> on the rudder, two strands were cut when the nircopress was cut off with a
> drmel tool.
>
> The question is whether we can reinstall a nicropress in the original
> position and then add one an 1/8" further?? or,
>
> Make splice two lengths of control cable with double nicropresses?? or,
>
>
> Is there any reason why a turnbuckle couldn't be used ouitside the
fuselage
> at the rudder??
>
> Thanks
>
>

A big pair of end nippers is a very useful tool when you need to remove
nicopress sleeves. Too late now, of course.

Tim Ward

[Dick[_1_]]

we were able to dremel down the center between the two cable segments but
removing the halfs apparently caused the damage.

Hope someone has some advise as the Bingelis books don't address repairs...

thanks
"Tim Ward" > wrote in message
...
>
> "Dick" > wrote in message
> news:g06Uj.5548$0L.5089@trnddc07...
>> Having to reject the last nicropress
>> on the rudder, two strands were cut when the nircopress was cut off with
>> a
>> drmel tool.
>>
>> The question is whether we can reinstall a nicropress in the original
>> position and then add one an 1/8" further?? or,
>>
>> Make splice two lengths of control cable with double nicropresses?? or,
>>
>>
>> Is there any reason why a turnbuckle couldn't be used ouitside the
> fuselage
>> at the rudder??
>>
>> Thanks
>>
>>
>
> A big pair of end nippers is a very useful tool when you need to remove
> nicopress sleeves. Too late now, of course.
>
> Tim Ward
>
>

[Stealth Pilot[_2_]]

On Wed, 07 May 2008 10:47:59 GMT, "Dick" > wrote:

>we were able to dremel down the center between the two cable segments but
>removing the halfs apparently caused the damage.
>
>Hope someone has some advise as the Bingelis books don't address repairs...
>
>thanks
>"Tim Ward" > wrote in message
...
>>
>> "Dick" > wrote in message
>> news:g06Uj.5548$0L.5089@trnddc07...
>>> Having to reject the last nicropress
>>> on the rudder, two strands were cut when the nircopress was cut off with
>>> a
>>> drmel tool.
>>>
>>> The question is whether we can reinstall a nicropress in the original
>>> position and then add one an 1/8" further?? or,
>>>
>>> Make splice two lengths of control cable with double nicropresses?? or,
>>>
>>>
>>> Is there any reason why a turnbuckle couldn't be used ouitside the
>> fuselage
>>> at the rudder??
>>>
>>> Thanks
>>>
>>>
>>
>> A big pair of end nippers is a very useful tool when you need to remove
>> nicopress sleeves. Too late now, of course.
>>
>> Tim Ward
>>
>>
>
there are swaged ends available that would correct your problem.
they require a swaging machine to fit them though.
they are about 3 inches long
look for ms20667 fork end, or ms20668 eye end, or ms21259 stud end.
or even an ms21260 turnbuckle end.
they are in the aircraft spruce cattledog.

Stealth Pilot

[Drew Dalgleish]

If it was my plane I'd throw the cable away and start over. Hiding the
2 broken strands under a new nico is a bad idea but adding a splice or
turnbuckle would work. Cable is cheap though so why not just change
the whole thing. As screw ups go that's only a little one.

On Wed, 07 May 2008 10:47:59 GMT, "Dick" > wrote:

>we were able to dremel down the center between the two cable segments but
>removing the halfs apparently caused the damage.
>
>Hope someone has some advise as the Bingelis books don't address repairs...
>
>thanks
>"Tim Ward" > wrote in message
...
>>
>> "Dick" > wrote in message
>> news:g06Uj.5548$0L.5089@trnddc07...
>>> Having to reject the last nicropress
>>> on the rudder, two strands were cut when the nircopress was cut off with
>>> a
>>> drmel tool.
>>>
>>> The question is whether we can reinstall a nicropress in the original
>>> position and then add one an 1/8" further?? or,
>>>
>>> Make splice two lengths of control cable with double nicropresses?? or,
>>>
>>>
>>> Is there any reason why a turnbuckle couldn't be used ouitside the
>> fuselage
>>> at the rudder??
>>>
>>> Thanks
>>>
>>>
>>
>> A big pair of end nippers is a very useful tool when you need to remove
>> nicopress sleeves. Too late now, of course.
>>
>> Tim Ward
>>
>>
>
>

[Gig 601Xl Builder]

Dick wrote:
> Having to reject the last nicropress
> on the rudder, two strands were cut when the nircopress was cut off with a
> drmel tool.
>
> The question is whether we can reinstall a nicropress in the original
> position and then add one an 1/8" further?? or,
>
> Make splice two lengths of control cable with double nicropresses?? or,
>
>
> Is there any reason why a turnbuckle couldn't be used ouitside the fuselage
> at the rudder??
>
> Thanks
>
>

A turnbuckle is outside the fuselage at the rudder horn is in the design
of the Zenith 601XL so if it doesn't get binded in anyway you should be OK.

[Dick[_1_]]

agreed, no hiding strands. however with all three of us big, heavy, stiff
guys, we can't get inside the fuselage <G>
"Drew Dalgleish" > wrote in message
...
> If it was my plane I'd throw the cable away and start over. Hiding the
> 2 broken strands under a new nico is a bad idea but adding a splice or
> turnbuckle would work. Cable is cheap though so why not just change
> the whole thing. As screw ups go that's only a little one.
>
> On Wed, 07 May 2008 10:47:59 GMT, "Dick" > wrote:
>
>>we were able to dremel down the center between the two cable segments but
>>removing the halfs apparently caused the damage.
>>
>>Hope someone has some advise as the Bingelis books don't address
>>repairs...
>>
>>thanks
>>"Tim Ward" > wrote in message
...
>>>
>>> "Dick" > wrote in message
>>> news:g06Uj.5548$0L.5089@trnddc07...
>>>> Having to reject the last nicropress
>>>> on the rudder, two strands were cut when the nircopress was cut off
>>>> with
>>>> a
>>>> drmel tool.
>>>>
>>>> The question is whether we can reinstall a nicropress in the original
>>>> position and then add one an 1/8" further?? or,
>>>>
>>>> Make splice two lengths of control cable with double nicropresses?? or,
>>>>
>>>>
>>>> Is there any reason why a turnbuckle couldn't be used ouitside the
>>> fuselage
>>>> at the rudder??
>>>>
>>>> Thanks
>>>>
>>>>
>>>
>>> A big pair of end nippers is a very useful tool when you need to remove
>>> nicopress sleeves. Too late now, of course.
>>>
>>> Tim Ward
>>>
>>>
>>
>>
>

[Jay Maynard]

On 2008-05-07, Dick > wrote:
> agreed, no hiding strands. however with all three of us big, heavy, stiff
> guys, we can't get inside the fuselage <G>

Can you use the old cable as a fish tape to pull the new cable through?
--
Jay Maynard, K5ZC http://www.conmicro.com
http://jmaynard.livejournal.com http://www.tronguy.net
Fairmont, MN (FRM) (Yes, that's me!)
AMD Zodiac CH601XLi N55ZC (ordered 17 March, delivery 2 June)

[Dick[_1_]]

now there's the answer I wanted. Just out of curiosity, what connection
method is used at the rudder pedals.
thanks
"Gig 601Xl Builder" > wrote in message
m...
> Dick wrote:
>> Having to reject the last nicropress
>> on the rudder, two strands were cut when the nircopress was cut off with
>> a drmel tool.
>>
>> The question is whether we can reinstall a nicropress in the original
>> position and then add one an 1/8" further?? or,
>>
>> Make splice two lengths of control cable with double nicropresses?? or,
>>
>>
>> Is there any reason why a turnbuckle couldn't be used ouitside the
>> fuselage at the rudder??
>>
>> Thanks
>
> A turnbuckle is outside the fuselage at the rudder horn is in the design
> of the Zenith 601XL so if it doesn't get binded in anyway you should be
> OK.

[Gig 601Xl Builder]

Dick wrote:
> now there's the answer I wanted. Just out of curiosity, what connection
> method is used at the rudder pedals.
> thanks


I don't have my plans here at the office they are at the airport but I
THINK. It is an AN115-21 cable shackle. If someone else doesn't pop up
with the answer shortly I can find out for you.

[Dick[_1_]]

possibly but last time I tried a few years ago but still fat <G>, my taped
connection came loose. now that I just wrote that maybe an electrical wire
butt splice would work. thanks for stimulation.
"Jay Maynard" > wrote in message
...
> On 2008-05-07, Dick > wrote:
>> agreed, no hiding strands. however with all three of us big, heavy, stiff
>> guys, we can't get inside the fuselage <G>
>
> Can you use the old cable as a fish tape to pull the new cable through?
> --
> Jay Maynard, K5ZC http://www.conmicro.com
> http://jmaynard.livejournal.com http://www.tronguy.net
> Fairmont, MN (FRM) (Yes, that's me!)
> AMD Zodiac CH601XLi N55ZC (ordered 17 March, delivery 2 June)

[Dick[_1_]]

thanks,would appreciate it. Are your cables 1/8"?

[Gig 601Xl Builder]

Dick wrote:
> thanks,would appreciate it. Are your cables 1/8"?
>
>

Trimmed a little tight on that one but the threading looks like your are
talking to me so yes, they are 1/8".

[Dick[_1_]]

<g>. just the start of one of those days where I can't get anything right .
Here's probably a better reference.

< I don't have my plans here at the office they are at the airport but I
THINK. It is an AN115-21 cable shackle. If someone else doesn't pop up with
the answer shortly I can find out for you.>

[Gig 601Xl Builder]

Dick wrote:
> <g>. just the start of one of those days where I can't get anything right .
> Here's probably a better reference.
>
> < I don't have my plans here at the office they are at the airport but I
> THINK. It is an AN115-21 cable shackle. If someone else doesn't pop up with
> the answer shortly I can find out for you.>
>
>

Dick, I just checked and surprisingly my memory was correct, it is
AN115-21 shackles.

There is a picture of this connection here.

http://peoamerica.net/N601WR/html/fuselage_1_180.html

[Dick[_1_]]

Thanks, good picture. My buddy is going to add brake lines from the Matco
units and a remote firewall mounted brake fluid reservoir.
"Gig 601Xl Builder" > wrote in message
m...
> Dick wrote:
>> <g>. just the start of one of those days where I can't get anything right
>> .
>> Here's probably a better reference.
>>
>> < I don't have my plans here at the office they are at the airport but I
>> THINK. It is an AN115-21 cable shackle. If someone else doesn't pop up
>> with the answer shortly I can find out for you.>
>
> Dick, I just checked and surprisingly my memory was correct, it is
> AN115-21 shackles.
>
> There is a picture of this connection here.
>
> http://peoamerica.net/N601WR/html/fuselage_1_180.html

[Gig 601Xl Builder]

Dick wrote:
> Thanks, good picture. My buddy is going to add brake lines from the Matco
> units and a remote firewall mounted brake fluid reservoir.

I decided the guy in the right seat didn't need brakes because I didn't
want to go to the hassle of a dual set up. I am going to add a parking
brake though.

[Dick[_1_]]

He also decided not to have right seat brakes but I was wondering what you
thought of the brake master reservoir on the firewall idea (so he doesn't
have to crawl inside and under the panel)?

Also what kind of parking brake are you thinking about?
Thanks

<"Gig 601Xl Builder" I am going to add a parking brake though.>

[Gig 601Xl Builder]

Dick wrote:
> He also decided not to have right seat brakes but I was wondering what you
> thought of the brake master reservoir on the firewall idea (so he doesn't
> have to crawl inside and under the panel)?
>
> Also what kind of parking brake are you thinking about?
> Thanks
>
> <"Gig 601Xl Builder" I am going to add a parking brake though.>
>
>


If you are talking about putting the brake master reservoir on the
engine side of the firewall, I don't like the idea. First, you have the
additional hole in the firewall, then you have the heat issue.

If you are talking about putting the reservoir on the inside of the
firewall I don't see what is gained.

[Dick[_1_]]

Respectfully, I'm not sure that heat is a problem: as long as the
reservoir is mounted away from exhaust pipes and oil cooler discharge, and
if necessary, could do some shielding like for gascolators or air duct like
those directed on magnetos.

I'd like to hear where others have a master reservoir located....

He has a removable top cowl skin between the firewall and instrument panel
for access to fuel tank and back of panel. Having the same removable skin on
my 601, it is easier to access my Matco rudder mounted brake units thru a
floor access panel. Each annual when I check the fluid level at the pedal
units and still pull the top skin to check instrument connections, hoses,
wiring, filters, I think how nice it would be to have an easily accessible
remote master reservoir<G>, hence the firewall aft side thought .

>> Dick wrote:
He also decided not to have right seat brakes but I was wondering what you
thought of the brake master reservoir on the firewall idea (so he doesn't
have to crawl inside and under the panel)?
Also what kind of parking brake are you thinking about?>>

> If you are talking about putting the brake master reservoir on the
engine side of the firewall, I don't like the idea. First, you have the
additional hole in the firewall, then you have the heat issue.

If you are talking about putting the reservoir on the inside of the
firewall I don't see what is gained.>

[Rich S.[_1_]]

"Gig 601Xl Builder" > wrote in message
m...

> I decided the guy in the right seat didn't need brakes because I didn't
> want to go to the hassle of a dual set up. I am going to add a parking
> brake though.

Were I to do it over again, I would delete the parking brake. I nine years,
I found little or no use for it. Wasted space and weight IMHO. I am glad I
put in brakes on both sides, though. When the day comes I need to sell it
(sob) I will want to be able to let the prospective buyer have brakes for
his pre-buy flights. When I bought my first Emeraude, there were no brakes
on the right and I was never able to get good taxi and landing practice. My
first flight on the left (after handing over the check) was very dicey as I
found I had inadequate room to operate the pedals on that side. The seller
had to take over in the middle of the takeoff 'cuz I was headed for the FBO.

For a dual setup, I built it with four master cylinders. I would instead use
two cylinders and link the toe brakes together mechanically.

Mrs. Murphy said, as she kissed the cow, "Each to his/her own liking". :)

Rich S.

[cavelamb himself[_4_]]

Dick wrote:
> Respectfully, I'm not sure that heat is a problem: as long as the
> reservoir is mounted away from exhaust pipes and oil cooler discharge, and
> if necessary, could do some shielding like for gascolators or air duct like
> those directed on magnetos.
>
> I'd like to hear where others have a master reservoir located....
>
> He has a removable top cowl skin between the firewall and instrument panel
> for access to fuel tank and back of panel. Having the same removable skin on
> my 601, it is easier to access my Matco rudder mounted brake units thru a
> floor access panel. Each annual when I check the fluid level at the pedal
> units and still pull the top skin to check instrument connections, hoses,
> wiring, filters, I think how nice it would be to have an easily accessible
> remote master reservoir<G>, hence the firewall aft side thought .
>
>
>>>Dick wrote:
>
> He also decided not to have right seat brakes but I was wondering what you
> thought of the brake master reservoir on the firewall idea (so he doesn't
> have to crawl inside and under the panel)?
> Also what kind of parking brake are you thinking about?>>
>
>>If you are talking about putting the brake master reservoir on the
>
> engine side of the firewall, I don't like the idea. First, you have the
> additional hole in the firewall, then you have the heat issue.
>
> If you are talking about putting the reservoir on the inside of the
> firewall I don't see what is gained.>
>
>
(bottom posting - even though it messes with the flow...)

I've always forud that the remote version was easier (and a lot neater!)
to bleed. Might have a higher capacity of fludi too, if built that way.

On the other hand, they are heavier, and have more opportunity to leak.

Ya pays yer money and takes yer choice...

Richard
--
(remove the X to email)

Now just why the HELL do I have to press 1 for English?
John Wayne