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Builder:
  Douglas Kupersmith
Location:
  Annandale, VA - USA
Aircraft:
  Zodiac 650 B
Total Build Hours:
  1352
Web Site:
  http://www.mykitlog.com/kuperda/

Date:  11-11-2019
Number of Hours:  3.00
Short Description:  Left Rudder Cable Fairing Replace 1

Based on TC recommendation, I began replacing the two rudder cable fairings near the aft end of the fuselage. My original fairing installation, completed before the rudder was installed, was at an angle where the rudder cables rubbed on the bottom of the fairing opening. Today I removed the left fairing and replaced it with a new fairing, but this time, with the rudder in place, I determined the proper angle for the fairing opening and drilled it out using a rivet hole feeler guide to match the original holes to the new fairing angle.

To finish the reinstallation, I also had to re-seat the nylon rudder fairlead inside the fuselage as it was removed with the fairing. Naturally, that section of the fuselage interior is inaccessible! To accomplish this, I ran a 10 foot, 20 gauge wire from the rudder cable exit point forward through the fuselage to the belly door. I then ran an AN3-17 bolt through the 3/16" slot on the fairlead, and tied the wire to the hole drilled near the tip of the bolt threads. By pulling the wire back out through the rudder cable hole, I was able to pull the fairlead into place, align it, and cleco one corner of the fairing to the airplane through the fairlead. After that, I re-seated the rudder cable into the fairlead slot, the rotated the fairing into place for final riveting.




Test fit of new fairing with adjusted rivet holes drilled out.





New fairing after re-seating the nylon fairlead on the inside of the fuselage.

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