I started with two Fox bellcranks. Drilled the centers out to 5/32", as it was sloppy on 1/8" wire. Then I cut a brass tube bushing to make it work with 1/8" wire.
Three more pieces of 5/32" brass tubing, as close to .095 as I could get them, and 4-40 hardware to fasten at the leadout and ball link connection points.
The leadout wire goes through 1/16" brass tubing that had previously been heated with a torch to facilitate bending. With two inches of wire sticking out of the end of the one inch tubing, I bent the tubing around a piece of 1/8" music wire until it had a lightbulb shape, spread it a little so it fit around the 5/32" brass tubing, wrapped with copper wire, and applied heat shrink. Bolted it all together with nylock nuts.
The 1/8" music wire post is supported top and bottom by 1/8" ply. Duracollars hold the post in position inside the two ply plates, and one more collar holds the bellcrank in place. The music wire extends through both ply plates and stops just shy of the center sheeting.
The only problem area I can see is the brass tubing on the leadouts rubbing on the brass tubing sandwiched between the bellcranks. Because the screws are tight, the sandwiched tubing is held fast and can't turn like a bearing. But I think that arrangement is better than the leadouts rubbing on the screw threads.
Other than that, I think it's bulletproof.
I know, a 4" Bellcrank would be preferable, but I have several of the Fox bellcranks on hand, so I thought I'd try to engineer me something.
It's going in a Banshee.
Thoughts? Comments? Recommendations?