CABLE HANDLES, GOOD AND BAD

I felt the need to offer some information on cable handles that I have made for 10 years and the differences in the other cable handles I have seen. I have enclosed a drawing of the slider that I make. As you can see the material is HDPE,high density polyethylene. I have found this to last for many years. In the drawing I point out that I have a radius on the incomming side as well as the outgoing side so the 49 strand aircraft stainless steel wire has no sharp edges to flex on. That is why it lasts so long. The cable is rounding the corner not sitting on an edge to fatigue it.

On a trip this morning to the LHS I took a look at the Brodak handle and was I supprised at what I saw. The cable exits through a steel plate with a hole drilled through it. That is why a cable will fail and that is why I agree with Paul Walker that cables can be dangerous, but not all cable handles are made that way.

I have seen some handles that offer cables that pas through a screw that is able to be moved up or down. Same problem here, if the cable passes thouough any metal plate or screw and does not have a raidused place to ride on, it is going to fail.

I think Bob Gieseki has used my handles for at least 10 years and has had 10,000 flights on them. No problem with breakage at all.

Bill Werwage also has used them for 10 years, what else do I have to say.

Not all cable handles are the same, please don't lump them all in the same group.

Dick,

You are right, of course. And a good friend, Heavy Stunt, just recently experienced the exact failure you predict with Brodak handle. His Impact lives on, but it was a very, very close call as to whether it was going to belly in or hit at an angle.

The truly scary part was the lack of warning signs: The cable was not frayed or in any apparent distress. It just broke clean as Bruce cranked in a quick hit of down control.

I am not suggesting anybody throw one of these handles away, but if you're not replacing the cable once a year you do in fact risk the loss of a model.

I've had 3/16" stainless military aircraft control cable break cleanly without warning running it over the edge of some angle iron (at a really low angle, about 15 degrees deflection) with only a hundred or so pounds of pressure on a winch (pulling a car onto a trailer with no roller at the end).

REALLY shocking how much that stress point reduced the strength of the cable. It wasn't fatigue either (first and only time I ever tried that!), just plain broke right then and there like putting a overhand knot in monofilament fishing line.

Tools

>I've had 3/16" stainless military aircraft control cable
>break cleanly without warning running it over the edge of
>some angle iron (at a really low angle, about 15 degrees
>deflection) with only a hundred or so pounds of pressure on
>a winch (pulling a car onto a trailer with no roller at the
>end).
>
>REALLY shocking how much that stress point reduced the
>strength of the cable. It wasn't fatigue either (first and
>only time I ever tried that!), just plain broke right then
>and there like putting a overhand knot in monofilament
>fishing line.
>
>Tools

The defining word is "edge". When the cable has an edge to ride on it will break. My cable flows around the curved slider hole. Thats why it lasts.

Thanks Dan,
As a mater of fact I will offer free replacement of any of my handle cables free. You just pay the postage both ways. Once a year. How about that for service.

I like the old small Sullivan handle for small airplanes. It has a thin tin strip with grommets. The cable makes a right angle turn (actually two) through the grommets. I've had two cable breaks, both with TD 09 powered Shark 15. The airplane was not harmed in either case. I now put small Tygon tubing over the cables and inspect them every flying session (same with other handles) and have had no more problem. My point is I think the cables broke due to repeated flexing at a small radius corner, rather than from being pulled very hard.

Considering the many months of labor that go into a competition stunter; sounds like your handle is cheap insurance. Do you still make those absolutely beautiful tool boxes?

"I don't know about this tuned pipe business. I practiced on that thing until my lips turned blue, and I still can't play a stinkin note."
"Homer J. Simpson"

I sure do. By the way the response to this thread has been a flood of e mails (orders). I guess finally my explanation got through.

Thank very very much!!!

Your pride in your product and your desire to make good stuff got through. I might have to sign up for a handle, too.

Thanks,
I have many in stock.

>Your pride in your product and your desire to make good
>stuff got through. I might have to sign up for a handle,
>too.

One would hope. Howard, I know your handle to be one which is very effective. But it looks as if a young child--or Marilou, possibly--put it together for you.

Dick:

Just a few words to add my name to your happy customer list. I've looked closely at my two cabled handles and see no wear at all. HOWEVER: the "no cable" handle you brought me at VSC has made a believer out of me.

It just kills me to agree with DirtyDan on something but I'll never buy another cabled handle again. The difference is noticeable and all for the better. I'll send an order before spring.

This just points out that everyone has a different feel that they want. Cable types have a different feel than hard point. There is no "best" for all fliers. Whatever works for you is what you need to use.
That is why I decided to make both styles, complete ready to go.

>Dick:
>
>Just a few words to add my name to your happy customer list.
>I've looked closely at my two cabled handles and see no wear
>at all. HOWEVER: the "no cable" handle you brought me at
>VSC has made a believer out of me.
>
>It just kills me to agree with DirtyDan on something but
>I'll never buy another cabled handle again. The difference
>is noticeable and all for the better. I'll send an order
>before spring.
>
>Jeff W

Jeff,

I almost missed this! Gotta love it...

LAST EDITED ON Oct-29-04 AT 05:46 PM (CDT)
 
OK, I have over 5000 flights on EZ-Just Hot Rock handles and never a failure of any kind. Still, since the question has come up, I've reconsidered. I am going to rework my stock of Hot Rocks of various modified sizes. I've figured out how to replace the cables with aircraft grade braided wire. The wire exits my modified handles through plywood spacers and guides. I will "bell mouth" the guides to avoid stress concentrations and I'm considering running the cables through fuel line tubing to just past the exit, again, to "cushion" the cable and provide a stress free exit from the handle.

Hot Rocks forever! (now that I'm resupplies with modifiable stock)