Fiber cable guide replacement

[shipljl]

Does anyone know where I can get material to replace the aileron cable guides? See the attached picture. What is the material called?

[Mark Julicher]

Re: Fiber cable guide replacement

John,

The material is phenolic. It is available in several forms (sheets, tubes, blocks) and can be purchased from Aircraft Spruce and other suppliers. I buy it online from U.S. Plastics. It is a composite of linen and resin and can be drilled, sawn, and machined

[shipljl]

Re: Fiber cable guide replacement

Thanks for the info.

John

[Robert Lees]

Re: Fiber cable guide replacement

When I cleaned mine up, they looked like new (although I see yours is cracked).

Phenolic is good. It is commercially available as an electrical insulating board, so if you know anyone in the HVAC (High Voltage AC) industry, they might be able to slide an offcut your way.

Incidentally, my other aileron cable guide looked like black nylon, although it was still riveted in with those pesky steel rivets, so was probably original.

[Robert Lees]

Re: Fiber cable guide replacement

Edit: I see you seem to appear have built-up (truss) ribs. Your fairlead seems to have cracked around the rivet holes (as would be expected).

The photo below shows the same fairlead in my post-war stamped rib, and they only used two of the rivet holes (although evidently the fairlead is the same).

[shipljl]

Re: Fiber cable guide replacement

I believe mine have been re-riveted because they have aluminum rivets holding them in place, not steel. My mechanic recommended replacing them and riveting with soft rivets. He said they would be less likely to cause the new material to crack.

[Robert Lees]

Re: Fiber cable guide replacement

I've had another look at your photo...there certainly looks like a mish-mash of rivets, etc there.

Soft rivets (or even #4 screws and nylock nuts) would work. These are not stressed parts...they are only cable guides.

[1938BF50]

Re: Fiber cable guide replacement

another option....

[Robert Lees]

Re: Fiber cable guide replacement

If you go that way, make sure the thimbles (cable ends) will pass through the fairleads (or that you have access to disassemble the fairleads in situ) for future cable inspection/replacement.