Yesterday while flying my Midwest 300XS, one of the rudder pull-pull cables broke. I was using 135# test, nylon covered leader line. One end was secured at the rudder with a 4-40 eyelet, and the other end was looped through the servo arm and crimped. The servo arm was a heavy duty Du-Bro arm made of composite material. The cable wore through where it looped through the hole in the servo arm. The moral to this story is not to secure the cable as I did. I replaced the cable and put 4-40 eyelets at the servo end. This provides a somewhat less sharp edge where the cable wraps through the eyelet. This is a temporary fix as I need to come up with a more satisfactory method. The old method lasted for over a hundred flights. I think I will play with the idea of a pulley at the servo end. I haven't decided to keep the eyelets at the rudder end or to try and enlarge the eyelet surface where the cable attaches. My real problem is with my two larger models, a 1/3rd and a 35% scale models that have the same system as my Midwest. Any suggestions would be appreciated.
Cajuncharley