Fairleads

[selje]

What are the length, OD, ID and material of the fairleads? Source? Are there ones that are split so they can be installed without removing the cables?

[hangarb7]

Re: Fairleads

I also would like some information on the fairleads. I plan to make some on my lathe that are split and held with a clip but I need a sample or at least some dimensions.

Believe it or not, I have had my plane since 2003 and it has no fairleads in those little pipes. I have to assume that they were not replaced when the airplane was recovered in 1989 or before.

Are others operating without fairleads? Doesn't seem to effect operation and my cables are pretty good with no burrs or even rubbing when the plane is at rest. Cables run right thru the middle of the little pipe.

Any help?

Thanks,

Jack
N44057

[mulwyk]

Re: Fairleads

Jack:
I have some original fairleads. I will post a drawing of them tomorrow with dimensions. They are not split, but should be. And they are made of some sort of primative, brittle plastic. You'd probably want to make replacements out of nylon.

I was just getting ready to have some made at a local machine shop. The hollow nylon rod is cheap (about $10 for 5 feet) and snap rings are only $7 for 50. But the lathe setup cost is a killer, it makes fairleads kinda pricey if you only get 10 made at a time.

If you are going to make some would you be willing to make an extra set for me?

Bob Gustafson

[Robert Lees]

Re: Fairleads

I made my own here (about 1/5 way down the page )

Hope this helps. The material is not important...as long as it's softer than the cable.

Rob

[Dan Carlson]

Re: Fairleads

You can find the fairleads at Aircraft Spruce. They are the split type with steel clips and are either 3/4" or 1" long by 3/4" OD. They are just a hair small in diameter, but if you put a little spooge on them first, they work just fine and cost around $2 a set.
Dan

[Richard Boyer]

Re: Fairleads

spooge?

Do I really want to know what that is??

Richard Boyer
N95791

[Ragwing nut]

Re: Fairleads

The real early ones are a hardboard paper of some type and can't be removed without destroying them. The next generation are phenolic, and if you are careful, the can be removed. The latest ones being made are plastic and too small for T-craft unless you glue them in. They are for Pipers. Has anyone tried calling the factory? I have just about used up all the ones I have here and will have to buy some for the next project.

Mike

[AlvinMcIver]

Re: Fairleads

Wag Aero has them on page 115 of the Jan 2006 catelog [part no M-035-000]. They fit "standard 7/8" x .058 round tube", whatever those dimensions are. A set is $1.99 but they may not be the right fit since they are a "direct replacement for Piper". For two bucks and the shipping it might be worthwhile finding out how close they are.
Alan

[hangarb7]

Re: Fairleads

Bob G,

Thanks for the offer. I think I would still like to get a sketch of what the fairleads look like. But I think I will also buy a set of Piper-type from AC supply or Wicks. If the pipe used in our birds is 7/8 OD, then at .058 wall that leaves .009" difference, but welding a pipe usually makes a little interference inside due to oxidation or bubbling of the metal, which would tighten the hold a little.

Depending on how tight the clip holds the piece inside the tube, we may be able to put a wrap of anti chafe tape on to make up the difference.

And I would make extras if we needed to do this but again, I am going to look into purchasing the Piper-type first.

I'll report back.

Thanks,

Jack

[mulwyk]

Re: Fairleads

Jack:
The attachment is a drawing of the Taylorcraft fairlead (on top) and the Piper split style fairlead (on bottom). I got a set of Piper fairleads from Spruce a few months ago and haven't used them.

There's three problems with the Piper fairleads. (1)They are too small in diameter for the T-Craft tubes, (2) they are too long and (3) the retainer ring is too small. If you install one on a T-Craft, it will have about 1/16 inch clearance around the diameter and about 1/4 inch horizontal clearance. And the retainer ring that they send with them is so small that it allows the fairlead to just fall right back out. Real bad fit.

However, I think you're right that the split Piper fairleads could be adapted to work on a Taylorcraft. Your idea about putting tape around the fairlead is great. The tape would take up the diameter clearance very nicely.

And I have tried using a snap ring in place of the plain retainer ring that comes with the fairlead. The ears on the snap ring make it wide enough that it keeps the fairlead from falling out of the tube.

Taking up the horizontal clearance (length) would be a little harder. I haven't tried it yet, but maybe we could cut 1/4 inch off the length of the fairlead and then put in another retainer ring groove closer to the head. The new groove could be cut in with a hacksaw blade or maybe even burned in with a soldering iron.

Like young Frankenstein said, "It could work!"

Bob Gustafson

[hangarb7]

Re: Fairleads

Bob,

I am going to purchase some Piper fairleads anyway. Duplicating the interior vortex shape on my old lathe would be timeconsuming.

I can make a centering puck for the Piper fairleads to fit over, using your snap ring idea to hold the halves firmly. Then chuck it in the lathe and cut a new groove. Then disassemble and cut the halves to length on the bandsaw.

The other idea might be to cut a plastic washer from some plastic pipe stock to take up the distance between the metal tube and the snap ring. Or some 4130 tubing would work also but would need to paint them.

Thanks for the drawing. I didn't realize that the Taylorcraft fairleads had a retainer clip at both ends. I like the shape of the Piper style better.

I'll report back.

Jack Dernorsek
N44057

[Wayne]

Re: Fairleads

The Aircraft Spruce fairleads worked fine for me with c clamps. The picture is out of focus but you will get the idea.

[hangarb7]

Re: Fairleads

Hi Wayne,

Something doesn't add up here with your picture. Are these the Spruce fairleads made for a Piper? If so they seem short enough to fit the Taylorcraft tubes. The comment previously is that the Piper style is too long for the TC tube. Why did yours seem to fit so well?

And what do you mean by C clamps? It appears that you are using a snap ring; is that what you mean?

Thanks,

Jack Dernorsek
N44057

[Wayne]

Re: Fairleads

Jack,

I don't remember them being designated for a Piper. Also I don't know the length but I did order them from Aircraft Spruce. It's been a couple of years ago and I could send you one if you want to look closer. You are correct about the snap ring, I just had the name wrong. Here is a picture of the rings with part numbers on the bag.

[mulwyk]

Re: Fairleads

OK, I think I have this fairlead thing figured out. The correct fairlead IS available from Aircraft Spruce, but it doesn't seem to be listed in their catalog. If you go to their website and enter the part number 40071-00 into the search box you'll find a "short fairlead segment" for $.83. The "fairlead segment" is exactly the right length for Taylorcraft, but slightly small in diameter. A couple turns of tape makes them fit perfectly.

A fairlead segment is half of a fairlead, so order 2 segments for each fairlead. You'll also need a "clip" (05-05700, $.27) or a snap ring for each fairlead. Details and photos here.

Bob Gustafson