Flap Pulley Wear

Several Bearhawk owners have reported wear observed on the inside of the exterior fuselage flap pulleys, generally at around 400 flight (landing) cycles. This appears to be caused by the flap cables changing direction in two planes at this point, and is more accentuated on the left pulley.

The pulley wears on the inside. It can be removed and flipped 180° to double the pulley life. It is easily observed on a routine inspection and easy to change.

Builder Graham Johnson has an innovative solution to the issue (below), sanctioned by Bob Barrows. Instead of using the standard shackle to attach the cable, Graham used a bolt. This allows the cable to be off-set to one side of the arm slightly, and allows a straighter cable run, with less pulley wear.