Fuselage 36 – Rudder cables

First task for today was to drill the rudder cable routing holes through the center section. I used a step bit (unibit) for the forward holes, but because of the bracket for mounting the floor plates, I could not do the same for the aft holes. I was able to get the aft hole started with a step bit, and then I used a number of incrementally larger bits through the forward hole. This allowed me to avoid hitting the floor mounting bracket. img_9226.jpeg

Here you can see the aft hole. It is drilled to 1/2″. img_9455.jpeg

Unfortunately, the length of the 5/8″ drill bit, when combined with my drill, is too long. The drill hits the mounting for the fuel selector valve, and as a result I cannot access the aft hole at the proper angle. My 90 degree drill extension will not accept the 5/8″ bit (even with a reduced diameter shank. So I’m not sure what I’m going to do. To be honest, I think I may grind a portion of the drill bits shank to fit in my 90 degree extension. We’ll see if another idea presents itself. img_9456.jpeg

As I was stalled on the rudder routing, I turned my attention to a rudder fairing. Apparently they sell some overpriced ones on Aircraft Spruce and some other places, but I also found some simple instructions for a do-it-yourself version. First cut a piece of .020 to 4″x4″, then mark out the measurements show. Note that I messed up the outer lines. The correct lines are in red. img_9229.jpeg

Start by bending the center to 90 degrees, and then bend the outer lines to 45 degrees. A hand seamer, some wood, and a vice are helpful. Here is the rudder cable exiting the fuselage in stock form.img_9230.jpeg

Here is the fairing I made following the instructions I stole from another builder here. Note that the fairing overlaps the skin joint. To correct this, I marked the location of the skin joint and then measured and marked a symmetrical portion on the upper flange of the fairing. This picture isn’t great, as the fairing will sit a little bit lower on the left to not interfere with the hole for the attachment of the protective tube. img_9231.jpeg

Here is the result after trimming and priming. I plan to secure the fairing with pro-seal. img_9234.jpeg

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