I am building a 1/4 scale Cap 232 and would like to know if nylon gear sets will hold in a single rudder servo setup.

I have been using JR 4721 with nylon gears with no problems up to 35%

One servo in the 1/4 scale // two in the 35%

EXCAP232

For the most part I agree with EXCAP232, but you should not use a hard link to the tail wheel. Flight loads should be no problem but the shock loads from the tail wheel may be many times stronger.

I want to knife edge loop with it so 45 degrees deflection should be what I need. As for torque, I figured 100 oz in.

I want a servo with about the same specs of the Hitec 5925 but without the expensive metal gears...

JR 4721 has 119 oz-in at 4.8 volts and is a real workhorse. I have one of these on the rudder of my UCD and Hitec 545 (5 poles) on the other surfaces. The JR is more expensive however the precision and speed is much better. The connection to the tail wheel is from a Dubro .40 size bracket and rubber band to the rudder.

EXCAP232

Until I got my 25% cap I never had a problem with servos. I have successfully stripped 5 servos and the last one made a big mess. Fortunately it was an easy repair but now I have to recover and I suck at that so who knows what'll happen to the plane now.

You could also try a Hitec 645MG its a high torque , metal gear, but its not very expensive.

I have used a hard link to the tail wheel once and it was the last time --> puts way too much unnecessary load to the servo.

Thanks for inputs.