Flex cable problem

[Seadweller]

All,

I'm building a mean machine and have it almost ready to go. It was a used hull I picked up cheap from someone at work. I'm running a CC 1518, 2 x 5S and a T180. It came with Aeromarine hardware - billet strut, 3/16th with bushings. I used a long piece f flex to align the stuffing tube and motor. When I tried to insert a new 0.150 cable in the strut so I could measure it for length the solid shaft part would not go into the strut. This is a new OSE 0.150 cable (UL-1). I also tried a new Hugely 0.150 cable and had the same problem. I pulled 2 cables out of existing boats (same types) and they do fit into the strut.

In the picture, the 2 cables on the right are the new ones that will not fit and the 2 on the left are used and do fit. I measured all the cables - the new ones are 0.186/7 and the used ones are at 0.185/6. I wondering what my options might be best - should I try to sand the new cables down a bit; or bore out the strut bushings or replace them with a speedmaster bushing (Product ID: ros-spds-014-bsf) which I have; or maybe run an old cable. I really didn't want to buy a new strut, but the speedmaster 21 would be an option. My intention for this MM is sport/play and experimentation - my 1st cat. Of course, then there's the Motley Crew...

Any suggestions would be appreciated.
Howard

[Fluid]

It is hard to believe that the "new' cables do not fit, your strut must have non-standard bushings, or they are damaged. I'd mount the "new" cables in an electric drill or drill press and sand down the strut bearing surfaces to match the "old" ones. Use 400 and 1500 grit paper with oil. But I'd like to see a photo of the strut and a description.



.

[RandyatBBY]

Jays method is close to what I do for my setups only I use a lathe and emery cloth to fit to my bearing setups where the hole is .187 in the ball bearing. If I am using lead Teflon bushings I ream the bushings with a .1875 reamer. Octura's shafts are .187. Long story short use Emory cloth and it will go fast.

[Seadweller]

Hi Fluid and Randy,

I'll give sanding the bearing surfaces a try. I'll also pull the strut and try and get some pictures. It appears to be the standard strut aeromarine uses on the MMs. I'll see about getting the pictures up later. One would think the used bushings would be worn larger than a standard 3/16 shaft.
Thanks.

[carlcisneros]

BEFORE you start the sanding, get an accurate measure of the diameter
of the solid shafts of the old and new ones.
also take a measurment of the bearing inside the strut if you can.

[RandyatBBY]

I was speaking about the bearing surface of the stub shaft is what I make smaller with the Emery cloth. I just wanted to make sure you understood what I was trying to convey. I only have to take off a few thousands of an inch. It is real hard to measure with out a set of micrometers.

[carlcisneros]

bearing surface

ooooohhhhhhhhhhhhhhhh,,,,,,,,,,,,,,,,,,

but if it were me, I would run a 3/16 bit through it first to bake sure the bearings were nice and cleaned up.

jmo

[sailr]

ooooohhhhhhhhhhhhhhhh,,,,,,,,,,,,,,,,,,

but if it were me, I would run a 3/16 bit through it first to make sure the bearings were nice and cleaned up.

jmo

Quickest and simplest solution!

[Seadweller]

Flex Shaft

All,

Thanks for the input. Attached are some picts of the strut with and w/o the flex shafts. One of the shafts is used the other 2 are new. One I started sanding the solid shaft part with 600 w/d with oil. I also ran a piece of cable w/ 600 grit through the strut. The strut bushings look ok; I don;t see any major cuts, pits or slices. I did measure the cable end shafts with a caliper - those were the numbers in the original post. There was 1 to 2 thou. difference between the used shaft and the new one. I need to see if I can measure the bushings. As far as I can tell the strut is a stock aeromarine 3/16 strut.