When making the first set of rudder cables, I did the best I could to avoid any kind of binding and had to choose between 2. The first being a slight contact with the aileron pushrod, OR, changing all the angles and dealing with a small amount of cable/pulley misalignment rub. Well I chose the wrong one. During my first High speed taxi run down the runway, I could feel every single detail of the cable strands rubbing against the pulley as it traveled through the pedals like a telephone wire. The throw was anything but smooth. This was NOT acceptable. It took me 4 hours, to re-make 2 cables, and change all the angles and throws to something that is now MUCH smoother. On top of that, the interference with the aileron pushrod and left rudder cable is only when the cable is relaxed and rudders are neutral, so there is no real danger for inflight failure. Still I will watch the cable closely at every inspection interval. All these cable woes are also leading me to change it all out to a quadruple pulley system as many have gone to who are not using firewall mounted brake cylinders. The bellcrank is not needed in my sysem, but this big overhaul of a job will have to wait until I have some time on this bird and time to install the system.
