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Page 53
CHAPTER EIGHT
SECTION 8.1
BOOM TRUSS (continued)
PHILLYSTRAN TRUSS (continued)
When securing the Phillystran truss cable, the rule of “don't saddle a dead horse” applies. You must be cer-
tain that the saddle portion of the wire clip is on the longer or “live” side of the Phillystran, and the U-bolt
section is on the “dead” or (short) side of the Phillystran. Because of this, how you thread the Phillystran
through the thimble is important. The lengths of the Phillystran are different on each side of the truss. It is
best to “trim as you go”, that way you can minimize the opportunity for error.
Locate the truss attachment plate (PN 10-1607-11) and connect to the boom using two 2” aluminum saddle
halves (PN 10-1601-22), two 5/16” x 3-1/2” hex head bolt (PN 60-0065) and two Nylock nuts (PN 60-0046).
The saddle set for the truss attachment plate goes in between the two bolts of the portion of the boom that
transitions from 2” to 1-3/4” as shown in
figure 8.12
. Position the saddle so that it is about 1/4” from the
hex head bolt closest to the mast plate as shown in
figure 8.13
.
When preparing the Phillystran truss, you will need to bring the Phillystran from below the thimble so that
the “dead” side is facing towards the sky. Insert the 3/16” thimble (PN 60-0048) into the middle hole on
the truss attachment plate as shown in
figure 8.14
. Loop the Phillystran around the thimble until approxi-
mately 8” of the Phillystran is on the “dead” side as shown in
figure 8.15
.
Figure 8.16
shows how to position
the two pieces of Phillystran cable into the wire clip saddle. Position the first of the four wire clips (PN 60-
0045) so that the wire clip is as close to the thimble as possible, as shown in
figure 8.17
. Tighten the wire
clip, alternating between each nut so that the tightening force is evenly distributed. Hold each portion of the
Phillystran in place while tightening, to ensure that a good mate is formed between the two cables. Wait 20
minutes and tighten some more, as cold-flow of the plastic usually occurs. A great way to do the initial
tightening is to use a 7/16” deep socket and hand turn, as shown in
figure 8.18
. This allows you to get pret-
ty tight and in good position on the two cables before doing the final tightening. Position the next wire clip
approximately 1 inch behind the first wire clip and tighten accordingly. Repeat with the remainder of the
wire clips as shown in
figure 8.19
.
Locate the plastic end cap (PN 60-0044) and push it onto the end of the Phillystran as shown in
figure 8.20
.
Secure
the Phillystran pieces and the cap at the end of the wire clips with electrical tape. Repeat the
above steps for truss on the opposite side of the boom after attaching the Phillystran to the boom truss
mast.
FIG. 8.18
FIG. 8.19
FIG. 8.17
FIG. 8.16
FIG. 8.14
FIG. 8.15
FIG. 8.13
FIG. 8.12
FIG. 8.20
