Rudder Cable Repacement

[Rick]

Can you remove them, inspect them, and replace the originals if they are in good condition? Or does replace mean the replacements must be new?

No way to inspect the cables without removing them. No way to remove the cables without cutting them. When I did mine, I thought about using the longer ones to replace the shorter ones, but in the end, you still have to make up at least 2 new cables (the longest ones), and put loops back on the other 6, so I think you're not really saving much by reusing them.

Now that I think about it, there may be a couple cables that you actually can inspect without cutting them (under the front seats maybe?) - I can't remember for sure how enclosed they are. Even so, I think you must REPLACE them because that's what it says in Chapter 4, even if an inspection were possible and did not show any wear...

[Star57]

I wonder if they coull be inspected by means of a remote video probe, just like a colonoscopy

[Antoine]

not dumb at all. would one need to have an STC done for that to become legal?

[Gary]

not dumb at all. would one need to have an STC done for that to become legal?

More than that since it is an airworthiness limitation for the airplane I am fairly certain it would be a big deal and Diamond would need to be involved.

[Rick]

The problem with doing a colonoscopy on a DA40 is that the anatomy is all wrong. The cables mostly run inside of plastic (or metal) protective tubes. Take a look at your rudder pedals - the cables there run through some metal S-shaped tubing. The longer cables that attach to the rudder itself run through long tubing in the tail and connect to the cable tension adjusters under the rear seat - the only part of those cables you can actually see are a few inches at each end. You have to pull the cables out of the tubing to inspect them, and that requires cutting off one end. I can't think of any way around that to make an inspection of the cable even if it was allowed.

[JimP]

What does is the typical cost of the cable repacement?

[Star57]

If we cant do a colonoscopy lets do an MRI...

I guess an Xray would do the trick if it was aproved....talk about bitting your nose to spite your face

Contiguous X-Rays would definetlly cost more than replacing the cables, so much for my bright ideas!
Im disapointed by my lack of brain mass... I may have to withdraw my proposal to be VP of marketting for Black Diamonds Aero

[Gary]

What does is the typical cost of the cable repacement?

It depends on who is doing it. Labor charges typically run 12 to 18 hours. The replacement cable kit from Diamond cost $300 to $400 a few years ago. Some guys buy the cable and parts at a lower cost and make the new cables for much less in parts cost but possibly more labor hours.

[Rick]

What does is the typical cost of the cable repacement?

It depends on who is doing it. Labor charges typically run 12 to 18 hours. The replacement cable kit from Diamond cost $300 to $400 a few years ago. Some guys buy the cable and parts at a lower cost and make the new cables for much less in parts cost but possibly more labor hours.

So if you're handy, and you can borrow the special crimping tool to make the loops, and you buy the parts yourself - you can replace them for maybe a hundred bucks and a day or two of work. You still need an A&P to sign off on it. All the seats and the baggage area need to be removed to get to the connections.

[Gary]

For the DIYer explicit instructions and photos are in this thread.
http://www.diamondaviators.net/forum/di ... t3774.html