Dec 20, 2020     Rudder cable system - (3 hours)       Category: Controls

Installing the rudder cable system per manual before the top skins go onto the tailcone. Including fitting the exit fairings for the rudder cables.

  Dec 22, 2020     Rudder cable system - (1.5 hours)       Category: Controls

More work on rudder cable system install.

  Nov 24, 2022     Mounted control stick assembly - (2 hours)       Category: Controls

Finished fitting control stick assembly together, had to remove cross torque tube from assembly and bend stop tabs upwards(in vise) so that they will contact stop bolts. Mounted the assembly to floor pan. Also started work on forward push pull tubes, sourced all needed parts and then cut and reamed two stop collars to fit over 35” push/pull tube.

  Dec 08, 2022     Aileron cable pulleys installed - (3 hours)       Category: Controls

Gathered parts, cut out and finished small cable holders and installed aileron control pulleys inside the fuselage. Many will have to be unattached to install cables later.

  Dec 10, 2022     Flap handle install - (1.5 hours)       Category: Controls

Gather parts and assemble flap handle assembly. Went ahead and mounted in fuselage to keep track of things. It will need to be partially unassembled to install the teleflex cables to the flaps once the wings are on.

  Dec 10, 2022     Aileron control cable attached to control stick - (.5 hour)       Category: Controls

Had not attached the control stick cable for ailerons to the stick assembly yet, I used one thick washer under the head of the bolt as a thin washer nearly let the castle nut go past the drilled hole in the bolt.

  Dec 15, 2022     Rear return cable for rudder - (2 hours)       Category: Controls

An update to the S-21 recently became available, rear rudder return cable. (Rear return cable, not rear rudder) This will prevent excess tension on the rudder cables if pressure is applied to both rudder pedals. I was waiting on the kit to arrive when I started on the panel work. Removed forward return cable pulley as it will now have an adjustable (for tension) support going through the firewall. Rear pulley mount was pretty tight quarters with the control sticks installed, but I did make it all work. Stainless steel rivets through floor and lower belly skin. There will be a cover over this whole assembly when interior is finished.

  Dec 16, 2022     Rear rudder return cable finish - (1 hour)       Category: Controls

Finished attaching the rear return cable and front return cable to rudder pedal control horns. Tensioned the assembly and attached rudder cables. (After these pictures were taken)

  May 13, 2023     Throttle & mixture cables anchored - (4 hours)       Category: Controls

Not all four hours on the anchoring of cables, also had to remove all input and output plugs from both LSE ignition boxes to reach and tighten the eyeball clamps on the two control cables. So while I had them off, I elected to secure the wires going out of the d-sub plugs a bit more securely than they had been.
After locating the direction that the retaining clamps needed to be oriented, I needed to remove the whole anchor assembly from the fuel injection servo to drill the second holes and debur them before re-assembly.
Finally reinstalled the input and output plugs on both ignitions. The anchor screw on these d-sub plugs are very difficult to reach and tighten which added to the time required.

  Mar 06, 2024     Balance ailerons and paint flap gap seals - (1 hour)       Category: Controls

Had used expanding foam previous day to make the plugs in the aileron spars. Measured approximately 58 ounces of small lead shot for each side and got the ailerons balanced. Unlike the elevator, they don't easily stay level on balance, however you can tell when you have enough weight when they go either forwards or back from level with equal propensity.

I had missed spraying the top of the flap gap seals that go against the fuse. So primed yesterday and final coated today. Picture is of primed surfaces.