pulley bushing

[ScottieB]

Hey guys,
Thought you might be interested in a problem I had, and the way it was solved. I'm gonna try to include some pictures of it if I can learn how to. Right behind the seats on both sides of the fuselage are some bushings that are for attaching the cable pulleys going to the ailerons. On my airplane, the bushing extended far enough to the outward side that it caused the nut (when put in place) to press against the fabric. This can be solved by removing a small amount of the length of that bushing before the fuselage is covered and before the pulley is mounted. It would be nearly impossible to do this after the fuselage is covered without damaging the covering. Johnny C. had the same dilemma with his plane.
Like I said, I'm gonna try to include some pictures of this, and in the picture I have installed a bolt with the threads showing. If you do decide to make this alteration, keep a couple things in mind - #1 - grind on the end of the bushing where the nut goes, NOT the end that the pulley sits against. #2 - If you make the bushing shorter, then the bolt supplied in the kit will be a little too long, so you'll have to change it. Hope this helps someone.

[xpflyr]

Can't you just put the bolt in the other end?

[Johnny C!]

Scott,
Nice write up.

John

[ScottieB]

After the plane is covered there's not enough room to squeeze the bolt in there between the covering and the bushing. If you install the pulley before you cover, then it's in the way when you're trying to do your upholstery. Much easier to simply grind the bushing down a little before you cover the fuselage IF you're aware of the problem beforehand. That's why I wanted to give you guys a "heads up".

[xpflyr]

After the plane is covered there's not enough room to squeeze the bolt in there between the covering and the bushing. If you install the pulley before you cover, then it's in the way when you're trying to do your upholstery. Much easier to simply grind the bushing down a little before you cover the fuselage IF you're aware of the problem beforehand. That's why I wanted to give you guys a "heads up".

Understood and thanks!

[jjacky]

Great and thanks for the heads up. About how much did you take off of the bushing?

[scubarider2]

I don't remember having this problem. Next time I am out at the hangar I will look what I did.
Dennis

[ScottieB]

I removed about 3/16" from mine. You could remove as much as you want as long as you don't grind into the tube that it's welded to. Make sure to leave a nice "square" end on the bushing for the nut to seat against.

[Johnny C!]

Since mine was covered when I ran into
this, I bought some locknuts, that I call
squeeze nuts. They were thinner than a
nylock.
I intend to put that on my once a month
preflight, just to keep an eye on them.

I

John

[danerazz]

I realize this is an OLD thread, but I forgot about it before I covered. I am going to try to use a dremel with a cut-off wheel and trim the bushing without burning the fabric off. The other option is using an AN320 low-profile castle nut and drilling a cotter pin hole very close to the end of a non-drilled bolt.

I need to think it over...

[Tralika]

I realize this is an OLD thread, but I forgot about it before I covered. I am going to try to use a dremel with a cut-off wheel and trim the bushing without burning the fabric off.

Wet towels under and around the cutting area will protect the fabric. It might be easier to use the castle nut, your not going to be removing that pulley very often.