Final assembly of rudder pedal stop

The gap between the tongues of the rudder pedals is approx 16mm. They do differ slightly, as expected from a welded construction. This matters when deciding just how much to file down the rudder cable bushings.

But the rudder cable assembly bushes are 17.3mm wide

So it was necessary to file these bushes - in situ - down taking great care to keep the surfaces flat an parallel, achieved by repeated changing of the file direction

Just how much to file down was informed by the measurement of the thickness of the stack on the bolt just adjacent to the bolt holding the rudder cable bushing. It would be no good for the cable bushings to differ to any significant degree from this value - the tongues of the rudder pedals will be made to flex very slightly as needed when clamping the bolts

But also the requirement to achieve a fit in the tongues of the rudder pedals.

I replaced the heatshrink tubing around the swaged ends of the rudder cables with self-amalgamating tape

Purchased from RS components

I placed some teflon anti-chafe tap on the impact surfaces of the (painted) rudder stops

Completed subassembly