Where are control cables most likely to break?

Control cables are most likely to break at locations where they pass over pulleys or through fairleads due to the increased stress and abrasion that occurs in these areas. The bending and friction associated with routing cables over pulleys or through fairleads create points of wear, which can weaken the cables over time.

When cables are routed around sharp turns or surfaces, the continuous flexing can compromise their integrity, leading to eventual failure. Additionally, when cables are not adequately lubricated or maintained, the risk of breakage increases substantially. The design of these components also means they are frequently the focal points for tension and movement, making them the most vulnerable to failure under operational stress.

While breaks can happen in the cockpit or at connection points with actuators, these areas generally experience less repetitive motion and stress compared to the pulleys and fairleads where the cables are actively bent and manipulated. Therefore, the likelihood of breakage is significantly higher in those sections.