I am finishing up a 38 Special profile version to be powered by a .40 OS max engine. Question, I have a 4 inch black plastic bellcrank ( actually looks like carbon). What would be the best way to attach the lead outs? Should I use a small tube for the wire to bear on or can I just thread the wire through the original size hole without it cutting into the bellcrank in service. I have been out of C/L since the middle sixties, but have built several c/l airplanes in the last three years. But have only flown two flights since getting back.

Tubing.  Even if you have to open up the holes a bit.

I use 3/32" OD tubing from the hobby shop.  There are folks who have found smaller tubing, which would work better, but I don't know where to get it (McMaster-Carr?).

Here's how I did it on my last plane.  Everything worked well, except the part about forgetting to thread the control system through the wing first, and thus having to unwrap the ends, thread on the leadout guide, and rewrap.

http://stunthanger.com/smf/index.php?topic=27915.msg273968#msg273968

Yup,  McMaster Carr

I also use the K&S 1/16 brass tubing and 135# test cable. It mikes at about .030. I get it at a good fishing store in a small spool, normally used for salt water leader material. Just for fun, anybody know who K and S are??

Most likely named for the owners... like Ken and Sam  (maybe?)

A couple of guys from the Chicago area who were well known free flight modelers late 30's and 40's era. Wally Simmers of Gollywock and Jabberwock fame and Joe Konefes of Buzzard Bombshell fame. Ya gotta be an old old timer to know trivia like this!