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cable tension

 
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wild.blue(at)verizon.net
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PostPosted: Sat Mar 01, 2008 1:25 am    Post subject: cable tension Reply with quote

Dan--

Take a look in your AC 43-13. There's a table of typical tensions for various standard cable sizes and strand counts at different temps. Don't have one here or I'd give you the page. They're all English (not metric) sizes so you may have to do a little interpolating. Or maybe Brian or Mark can give you the modulus of expansion for steel (sometimes the little gray cells fail me, but I think its about .01'/100'), which is about the same as for concrete, and the formula for catenary sag vs. tension (if that has anything to do with it) so you could calculate it. Just kidding.

Wish I could go to SnF, tho it be looka like spring lately roun hya. Sometimes. Maybe.


Jerry Painter
chief pilot, CFI, A&P, airport bum,
permanent latrine orderly &c.

Wild Blue Aviation
Arlington Municipal Airport (KAWO)
[b]Hangar A-6
19203 59th Dr. NE[/b]
Arlington, WA 98223
425-876-0865
JP(at)FlyWBA.com (JP(at)FlyWBA.com)
http://www.FlyWBA.com

[quote][b]


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wlannon(at)persona.ca
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PostPosted: Sat Mar 01, 2008 9:19 am    Post subject: cable tension Reply with quote

Good Morning Jerry;

I can't recall seeing a tension table in 43-13. As I understand it cable tension is affected by thermal expansion of aluminium airframe structure probably more than the cable itself. If so a "generic" table would be of little value and may be counter productive.
However, I have been known to be wrong so will check 43-13 later and get back.
It is definitely starting to look like spring is here!

Cheers;
Walt


[quote] ---


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viperdoc(at)mindspring.co
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PostPosted: Sat Mar 01, 2008 10:40 am    Post subject: cable tension Reply with quote

What? You are down to 3 feet of snow and the ice on you short hairs has melted back a couple of inches?
Now I know spring is near for us down here in LA (lower Alabama). The Robins came back a couple of weeks ago, the grass is turning green, the dogwoods are starting to bloom, and the F&^%$#(at) TORNADOS are BACK!
Doc

From: owner-yak-list-server(at)matronics.com [mailto:owner-yak-list-server(at)matronics.com] On Behalf Of Walter Lannon
Sent: Saturday, March 01, 2008 11:14 AM
To: yak-list(at)matronics.com
Subject: Re: cable tension



Good Morning Jerry;



I can't recall seeing a tension table in 43-13. As I understand it cable tension is affected by thermal expansion of aluminium airframe structure probably more than the cable itself. If so a "generic" table would be of little value and may be counter productive.

However, I have been known to be wrong so will check 43-13 later and get back.

It is definitely starting to look like spring is here!



Cheers;

Walt




[quote]
----- Original Message -----

From: Jerry Painter (wild.blue(at)verizon.net)

To: Yak List (yak-list(at)matronics.com) ([email]yak-list(at)matronics.com)[/email])

Sent: Saturday, March 01, 2008 1:20 AM

Subject: cable tension



Dan--



Take a look in your AC 43-13. There's a table of typical tensions for various standard cable sizes and strand counts at different temps. Don't have one here or I'd give you the page. They're all English (not metric) sizes so you may have to do a little interpolating. Or maybe Brian or Mark can give you the modulus of expansion for steel (sometimes the little gray cells fail me, but I think its about .01'/100'), which is about the same as for concrete, and the formula for catenary sag vs. tension (if that has anything to do with it) so you could calculate it. Just kidding.



Wish I could go to SnF, tho it be looka like spring lately roun hya. Sometimes. Maybe.



Jerry Painter

chief pilot, CFI, A&P, airport bum,

permanent latrine orderly &c.



Wild Blue Aviation

Arlington Municipal Airport (KAWO)

Hangar A-6

19203 59th Dr. NE

Arlington, WA 98223

425-876-0865

JP(at)FlyWBA.com (JP(at)FlyWBA.com)

http://www.FlyWBA.com



Quote:
[b]


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brian-1927(at)lloyd.com
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PostPosted: Sat Mar 01, 2008 11:11 am    Post subject: cable tension Reply with quote

On Mar 1, 2008, at 1:20 AM, Jerry Painter wrote:

Quote:
Dan--

Take a look in your AC 43-13. There's a table of typical tensions
for various standard cable sizes and strand counts at different
temps. Don't have one here or I'd give you the page. They're all
English (not metric) sizes so you may have to do a little
interpolating. Or maybe Brian or Mark can give you the modulus of
expansion for steel (sometimes the little gray cells fail me, but I
think its about .01'/100'), which is about the same as for concrete,
and the formula for catenary sag vs. tension (if that has anything
to do with it) so you could calculate it. Just kidding.

You forgot to account for differential expansion of the aluminum
structure. That is what causes the change in tension. The coefficient
of expansion for the steel cable is less than the coefficient of
expansion for the aluminum structure. So the airframe "shrinks" more
than the cable does when it is cold causing the cable to lose tension.

Here is a listing of coefficients of expansion for various materials.
You will find aluminum near the top and various steels in the middle.

http://www.handyharmancanada.com/TheBrazingBook/comparis.htm

Oh, and don't forget the modulus of elasticity (stretch) of the steel.
That is how you apply the preload. That will also tell you how much
the tension will change when you change the length with temperature.

So if you start with a slack cable, modulus of elasticity will tell
you how much the tension will change for a give change in length
(stretch). The difference in coefficient of expansion of steel vs.
aluminum (only valid for all-aluminum airframes -- steel tube
airframes change the equation as the steel tubing will have the same
coefficient of expansion as the cable) tells you how much the length
will change with temperature thus letting you calculate a new tension
value.

See, this stuff is childs play.

--

Brian Lloyd Granite Bay Montessori
brian AT gbmontessori DOT com 9330 Sierra College Blvd.
+1.916.367.2131 (voice) Roseville, CA 95661, USA
http://www.gbmontessori.com

I fly because it releases my mind from the tyranny of petty things . . .
— Antoine de Saint-Exupéry

PGP key ID: 12095C52A32A1B6C
PGP key fingerprint: 3B1D BA11 4913 3254 B6E0 CC09 1209 5C52 A32A 1B6C

--
Brian Lloyd 3191 Western Drive
brian HYPHEN 1927 AT lloyd DOT com Cameron Park, CA 95682
+1.916.367.2131 (voice) +1.270.912.0788 (fax)

I fly because it releases my mind from the tyranny of petty things . . .
— Antoine de Saint-Exupéry

PGP key ID: 12095C52A32A1B6C
PGP key fingerprint: 3B1D BA11 4913 3254 B6E0 CC09 1209 5C52 A32A 1B6C


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brian-1927(at)lloyd.com
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PostPosted: Sat Mar 01, 2008 1:58 pm    Post subject: cable tension Reply with quote

Quote:
Oh, and don't forget the modulus of elasticity (stretch) of the
steel. That is how you apply the preload. That will also tell you
how much the tension will change when you change the length with
temperature.

Before Mark jumps on me for making a mistake, let me make this more
clear. The modulus of elasticity tells you how much a given stretch
will change the tension (force) or vice versa, i.e. how much the
length will change when you apply a given force (think of a spring
here). When the cable and the airframe change size with a decrease in
temperature (coefficient of expansion), the airframe shrinks more than
the steel cable does. This causes the stretch on the cable to be
reduced and therefore the tension on the cable to be reduced. How
*much* the tension changes is a function of the modulus of elasticity.

Is that better?

--
Brian Lloyd 3191 Western Drive
brian HYPHEN 1927 AT lloyd DOT com Cameron Park, CA 95682
+1.916.367.2131 (voice) +1.270.912.0788 (fax)

I fly because it releases my mind from the tyranny of petty things . . .
— Antoine de Saint-Exupéry

PGP key ID: 12095C52A32A1B6C
PGP key fingerprint: 3B1D BA11 4913 3254 B6E0 CC09 1209 5C52 A32A 1B6C


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wlannon(at)persona.ca
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PostPosted: Sat Mar 01, 2008 5:36 pm    Post subject: cable tension Reply with quote

Geez Brian that's what I was trying to say.
Cheers;
Walt
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wlannon(at)persona.ca
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PostPosted: Sat Mar 01, 2008 5:36 pm    Post subject: cable tension Reply with quote

Snow long gone. Playing golf tomorrow. What the hell is a tornado???

Walt
[quote] ---


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fish(at)aviation-tech.com
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PostPosted: Sat Mar 01, 2008 7:02 pm    Post subject: cable tension Reply with quote

Doc,

Had a typical california day here in the high desert(Near
Los Angeles), 70 deg with a light wind. Unfortunatly I had
surgery on Thurs and can't take advantage of the good
weather right now.

Fly Safe
John Fischer
Yak-52, N213YA

----- Original Message Follows -----
From: "Roger Kemp M.D." <viperdoc(at)mindspring.com>
To: <yak-list(at)matronics.com>
Subject: RE: cable tension
Date: Sat, 1 Mar 2008 12:31:04 -0600

[quote] What? You are down to 3 feet of snow and the ice on you
short hairs has melted back a couple of inches?

Now I know spring is near for us down here in LA (lower
Alabama). The Robins came back a couple of weeks ago, the
grass is turning green, the dogwoods are starting to bloom
, and the F&^%$#(at) TORNADOS are BACK!

Doc



From: owner-yak-list-server(at)matronics.com
[mailto:owner-yak-list-server(at)matronics.com] On Behalf Of
Walter Lannon Sent: Saturday, March 01, 2008 11:14 AM
To: yak-list(at)matronics.com
Subject: Re: cable tension



Good Morning Jerry;



I can't recall seeing a tension table in 43-13. As I
understand it cable tension is affected by thermal
expansion of aluminium airframe structure probably more
than the cable itself. If so a "generic" table would be of
little value and may be counter productive.

However, I have been known to be wrong so will check 43-13
later and get back.

It is definitely starting to look like spring is here!



Cheers;

Walt





---


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viperdoc(at)mindspring.co
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PostPosted: Sat Mar 01, 2008 7:31 pm    Post subject: cable tension Reply with quote

Apologies, for some reason I was thinking you were in the frigid northwest.
My mistake.
Sorry about the surgery. It can be a pain sometimes. Can see why you would
not want to go flying. Hope all comes out okay.
Doc

--


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viperdoc(at)mindspring.co
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PostPosted: Sat Mar 01, 2008 8:07 pm    Post subject: cable tension Reply with quote

A really big sucking wind! Generally 400 yds wide and 160 mph that’s over in 10-15 seconds! Kind of like a bad divorce. Sucks you dry and destroys your life all in a heartbeat,.
Flying tomorrow with the guard. Golf is sheer mental torture. The only game I know that I am more pissed off after the game than before I started. The only game I know where that little dimpled ball has the ability take my personality from laid back to Tasmanian devil in one heartbeat.
Gave that game up for lent!
Doc

From: owner-yak-list-server(at)matronics.com [mailto:owner-yak-list-server(at)matronics.com] On Behalf Of Walter Lannon
Sent: Saturday, March 01, 2008 7:22 PM
To: yak-list(at)matronics.com
Subject: Re: cable tension



Snow long gone. Playing golf tomorrow. What the hell is a tornado???



Walt
[quote]
----- Original Message -----

From: Roger Kemp M.D. (viperdoc(at)mindspring.com)

To: yak-list(at)matronics.com (yak-list(at)matronics.com)

Sent: Saturday, March 01, 2008 10:31 AM

Subject: RE: cable tension



What? You are down to 3 feet of snow and the ice on you short hairs has melted back a couple of inches?
Now I know spring is near for us down here in LA (lower Alabama). The Robins came back a couple of weeks ago, the grass is turning green, the dogwoods are starting to bloom, and the F&^%$#(at) TORNADOS are BACK!
Doc

From: owner-yak-list-server(at)matronics.com (owner-yak-list-server(at)matronics.com) [mailto:owner-yak-list-server(at)matronics.com] On Behalf Of Walter Lannon
Sent: Saturday, March 01, 2008 11:14 AM
To: yak-list(at)matronics.com
Subject: Re: cable tension



Good Morning Jerry;



I can't recall seeing a tension table in 43-13. As I understand it cable tension is affected by thermal expansion of aluminium airframe structure probably more than the cable itself. If so a "generic" table would be of little value and may be counter productive.

However, I have been known to be wrong so will check 43-13 later and get back.

It is definitely starting to look like spring is here!



Cheers;

Walt




Quote:

----- Original Message -----

From: Jerry Painter (wild.blue(at)verizon.net)

To: Yak List (yak-list(at)matronics.com) ([email]yak-list(at)matronics.com)[/email])

Sent: Saturday, March 01, 2008 1:20 AM

Subject: cable tension



Dan--



Take a look in your AC 43-13. There's a table of typical tensions for various standard cable sizes and strand counts at different temps. Don't have one here or I'd give you the page. They're all English (not metric) sizes so you may have to do a little interpolating. Or maybe Brian or Mark can give you the modulus of expansion for steel (sometimes the little gray cells fail me, but I think its about .01'/100'), which is about the same as for concrete, and the formula for catenary sag vs. tension (if that has anything to do with it) so you could calculate it. Just kidding.



Wish I could go to SnF, tho it be looka like spring lately roun hya. Sometimes. Maybe.



Jerry Painter

chief pilot, CFI, A&P, airport bum,

permanent latrine orderly &c.



Wild Blue Aviation

Arlington Municipal Airport (KAWO)

Hangar A-6

19203 59th Dr. NE

Arlington, WA 98223

425-876-0865

JP(at)FlyWBA.com (JP(at)FlyWBA.com)

http://www.FlyWBA.com



Quote:
[b]


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fougapilot



Joined: 20 Jul 2007
Posts: 88
Location: Flat on my back with minimum airspeed

PostPosted: Sun Mar 02, 2008 4:48 am    Post subject: Re: cable tension Reply with quote

Lower Alabama???

I'll take my snowbank over tornados, hurricane or earthquakes any days of the week thank yo very much Wink

all joking apart, thanks for the replies.

Dan


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wild.blue(at)verizon.net
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PostPosted: Sun Mar 02, 2008 10:20 am    Post subject: cable tension Reply with quote

Gents--

In the ultimate sense, what you say about differential (aluminum) aircraft structure expansion/contraction being more of a relative factor for change in cable tension than the (steel) cables is, of course, true. Aluminum has a higher expansion rate than steel.  But we're talkin' little bitty airplanes here. Unless we're talkin' 'bout BIG airplanes and BIG changes in temperature it ain't hardly nothin.' That's why none (that I know of--which, admittedly, isn't much) of our little GA Yak-sized, un-pressurized, low altitude, short range airplanes has automatic temperature compensating cable tension adjusters (surely, someone will find a contradictory example, no?). Because the structures are so small the small temperature changes we usually encounter are simply not a factor--except when you set the initial tension.  Then, of course, you do want to compensate for temperature so the load will stay in the ballpark at all temps. The risk is that cables set to a "normal" tension in a cold environment could become so tight in high temps that control friction will go up and structural damage could occur. But again, probably unlikely with our little airplanes unless you really, really overdo it.

HSAT, Joe, you're right. There is no table in 43-13 (that I could find). I haven't had a chance to look through other standard FAA texts, but I did find a "typical" cable tension and temperature compensation table for various cable sizes in one of Dale Crane's books (Airframe Volume 1: Structures, fig. 4-42, p. 296, published by ASA--and no doubt taken straight from one of the FAA AC's), which I forwarded to Dan off list.

Crane's table shows that the (recommended) tension (for the hypothetical "typical" airplane) on a 1/8" 7X19 cable would be 34 lbs. at negative 40 degrees F (pretty damn cold!), and recommends 100 lbs E at plus 160 degrees F (really, really hot!). At 59 degrees F (standard day) the tension would be about 65 lbs. That's quite a broad range of acceptable tension (66 lbs. over 200 degrees F). Crane's table also says "values include 10% structural deflection." Hmmm.

But the real question, still, is what is the mfr's "recommended" tension at some given temperature. Is it the same as Crane's "typical" chart? I don't know and worth looking into. That "recommended" tension is what "compensation" has to be applied to. My guess is it will be very close to what's shown in Crane's "typical" table, just as bolt torques nearly always are "typical" for a given size.  Unless you grossly exceed "typical" values on the high side you're "probably" gonna be OK.

But do the homework, find the mfr's recommended value. And forget that plan to strap on those JATO bottles so you can fly nonstop from Coldfoot to Riyadh at 60,000 feet some fine winter day!


Jerry Painter
chief pilot, CFI, A&P, airport bum,
permanent latrine orderly &c.

Wild Blue Aviation
Arlington Municipal Airport (KAWO)
[b]Hangar A-6
19203 59th Dr. NE[/b]
Arlington, WA 98223
425-876-0865
JP(at)FlyWBA.com (JP(at)FlyWBA.com)
http://www.FlyWBA.com

[quote][b]


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brian-1927(at)lloyd.com
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PostPosted: Sun Mar 02, 2008 1:16 pm    Post subject: cable tension Reply with quote

Quote:
tension adjusters (surely, someone will find a contradictory
example, no?). Because the structures are so small the small
temperature changes we usually encounter are simply not a factor--
except when you set the initial tension. Then, of course, you do
want to compensate for temperature so the load will stay in the
ballpark at all temps.

If you have to compensate for temperature then the variation isn't so
small.

For example, if one were doing this in an airframe with a steel-tube
frame, the coefficient of expansion of the airframe would be the same
as for the cable. Therefore there would be no change with temperature
as both the cable and airframe would expand/contract at the same rate
with the temperature change. Sine we DO see a difference and we DO
compensate, the change is NOT small enough to ignore.

Quote:
The risk is that cables set to a "normal" tension in a cold
environment could become so tight in high temps that control
friction will go up and structural damage could occur. But again,
probably unlikely with our little airplanes unless you really,
really overdo it.

That is probably true but it is clear that it IS an issue and must be
done correctly.

Quote:
HSAT, Joe, you're right. There is no table in 43-13 (that I could
find).

There can't be. It is airframe-dependent.

Quote:
I haven't had a chance to look through other standard FAA texts, but
I did find a "typical" cable tension and temperature compensation
table for various cable sizes in one of Dale Crane's books (Airframe
Volume 1: Structures, fig. 4-42, p. 296, published by ASA--and no
doubt taken straight from one of the FAA AC's), which I forwarded to
Dan off list.

Crane's table shows that the (recommended) tension (for the
hypothetical "typical" airplane) on a 1/8" 7X19 cable would be 34
lbs. at negative 40 degrees F (pretty damn cold!), and recommends
100 lbs. at plus 160 degrees F (really, really hot!). At 59 degrees
F (standard day) the tension would be about 65 lbs. That's quite a
broad range of acceptable tension (66 lbs. over 200 degrees F).
Crane's table also says "values include 10% structural deflection."
Hmmm.

Well, if the airplanes are of the same order, sizewise, i.e. if the
cable lengths are similar and the distance from trim wheel to trim-tab
is similar, you will have similar adjustment range.

Quote:
But the real question, still, is what is the mfr's "recommended"
tension at some given temperature. Is it the same as Crane's
"typical" chart? I don't know and worth looking into. That
"recommended" tension is what "compensation" has to be applied to.
My guess is it will be very close to what's shown in Crane's
"typical" table, just as bolt torques nearly always are "typical"
for a given size. Unless you grossly exceed "typical" values on the
high side you're "probably" gonna be OK.

Actually bolt torque is not "typical". It is exacting as it is
determined by material, and thread pitch to give the proper amount of
"stretch" to the fastener. The only thing is that it has an acceptable
range.

Quote:
But do the homework, find the mfr's recommended value. And forget
that plan to strap on those JATO bottles so you can fly nonstop from
Coldfoot to Riyadh at 60,000 feet some fine winter day!

I agree ... if you can find the manufacturer's recommended value. But
not having that you can figure out what the cable and airframe
structures supporting the cable will allow without exceeding their
limits. Frankly, the structure, e.g. the idler fiddles, mounting
brackets, etc., are the limiting factor, not the cable itself. You
don't want the temperature getting so high on a hot day that the
mounting structures are deformed. So you pick a minimum acceptable
cable tension at the low temp, figure the distance, calculate the
differential length change based on coefficient of expansion
(expansion of Al minus expansion of steel), and then apply the modulus
of elasticity of the steel cable to determine how much the tension
will increase.

Believe it or not, this is NOT rocket science.

And, yes, it is MUCH easier to use the manufacturer's recommendations
because they have already done this work for you.

--
Brian Lloyd 3191 Western Drive
brian HYPHEN 1927 AT lloyd DOT com Cameron Park, CA 95682
+1.916.367.2131 (voice) +1.270.912.0788 (fax)

I fly because it releases my mind from the tyranny of petty things . . .
— Antoine de Saint-Exupéry

PGP key ID: 12095C52A32A1B6C
PGP key fingerprint: 3B1D BA11 4913 3254 B6E0 CC09 1209 5C52 A32A 1B6C


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PostPosted: Sun Mar 02, 2008 6:37 pm    Post subject: cable tension Reply with quote

More on cables;

The CJ6 Overhaul (Structural Repair) Manual undoubtedly has a temperature compensating table. However that manual to the best of my knowledge has not been translated to English so except for a few of the illustrations it is useless.

As a result I have been tensioning the cables with reference to the Harvard/T6 specifications. I initially checked undisturbed (presumably) cables on aircraft as received from China and determined they were within + 5lb of the Harvard specs. at 60 to 70 deg.F. Since the Chinese cable is 0.020" larger in dia. (0.145") one would expect a small increase in tension.

Some may suggest that procedure is unacceptable since the Harvard fuselage utilizes both steel tube and semi-monocoque aluminium alloy structure. However, the ailerons are also cable operated and the cable runs are of similar length in totally al. alloy structure. One must at some time make some assumptions and I have assumed that North American developed their tension table based on the aileron system. There is only one table.

As Brian has mentioned the most critical part of the cable system is the attachment of pulley brackets. The loads are highly concentrated at these points and one should be very careful to not over tension.

Jerry, I believe, mentioned that these are not "English" cables. They very well may be of British design which was quite different than the SAE cable standards we are familiar with.
Quite possible the current British standards are the same as the FAA but that was not the case when the Yak18, 18A and, by extension, the CJ were designed.

British cables were identified NOT by diameter but rather by breaking strength.
For example a 20CWT cable had a break strength of 2160 lb. (20 X 108) whether the cable was manufactured from carbon steel OR corrosion resistant steel. The CRES cable was of larger diameter.
A standard 1/8" cable has a break strength of 2000lb in carbon steel and 1760 lb in CRES. Since the pneumatic systems on the CJ are carbon copies of the Hurricane and Spitfire etc. it is quite possible the cables are as well.

Cheers;
Walt
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PostPosted: Mon Mar 03, 2008 9:13 am    Post subject: cable tension Reply with quote

Brian and Joe--

I think that's what I said? My guess is T-6 specs are very close, if not the same as Yakstuff, and given that the range of acceptable tensions on any given day is probably R E A L L Y B I G, differences (if any) between T-6's, "typical" and Yak/CJ data are not likely to be a serious issue. Auto temp compensators in little airplanes? None that I know of. Yes, check the specs, always better than a WAG, and apply compensation, especially if you encounter big variations in temp. But barring specific data to the contrary, "typical" (or T-6) probably works just fine. 

So howzabout something else? Here's a little -52/Nanchang ACM vid http://vids.myspace.com/index.cfm?fuseaction=vids.individual&videoid=29080478


Jerry Painter
chief pilot, CFI, A&P, airport bum,
permanent latrine orderly &c.

Wild Blue Aviation
Arlington Municipal Airport (KAWO)
[b]Hangar A-6
19203 59th Dr. NE[/b]
Arlington, WA 98223
425-876-0865
JP(at)FlyWBA.com (JP(at)FlyWBA.com)
http://www.FlyWBA.com

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