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Rob,

To answer your second question, yes, I've installed the right rudder cable
over the spar.  I felt the same as you that the straight run, over the spar,
was the smart thing to do.  To help with the problem of clearance in the
console (there's a lot of stuff to go in there) I ran the cable through the
prepreg of the left side of the console.  I used a long 1/8" drill bit to
run a hole through the honeycomb and then pushed in the rudder cable casing.
Its completely out of sight and straight.  Just make sure that it's location
won't interfere with your installation of the trim mechanism.

Regarding your first question, I seem to remember that the difference in
height of the blister didn't make any difference in how the rudder cable
"plumbed" to the rudder.  The attach point of the rudder cable is far enough
from the blister that the angle of the cable exiting the blister is
virtually the same.  Note that the difference in height of the blisters on
my plane was about 1/8" to 1/4".  Yours may be greater.  I don't think that
many builders do anything about the difference although it is an easy job to
relocate one or the other. (I did and I'm sure that Jim did also).  Get them
even with each other and then since you're building the rudder later you'll
be able to align the bottom rudder hinge with the cable exits.  Note also
that a couple of washers between the rudder cable attach bracket and the
cable end can help line things up.

Hal   (N360HW)

LML website:   http://www.olsusa.com/Users/Mkaye/maillist.html
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Please send your photos and drawings to marvkaye@olsusa.com.