Dave, I don't use a adjustable handle on my combat planes. My lines are exact length using a button style bellcrank. 60' center to center. Using leadouts to the tip would be consistently changing from plane to plane therefore I keep them all the same. We pull test prior to a match and inspect at the designated area. Unfortunately, more than once the failure I mentioned only happened in the area subjected to wear.

This is how I have been doing my PowerPro Spectra, very simple using Sullivan 80# clips. Never had a line failure or knot come loose. And no fraying.

I have been using 65# test Spectra lines, even on my heavy Vector 40 at 62 oz. Concerning overall strength, two 65# test lines to a model would total 130#. In level flight, my Vector probably has a pull of say 10# (5# per line). Or a safety factor of 13.

Some pilots are using 80# test. The only reason to do so that I can think of would be for lower stretch. But 80# is surely not needed for overall strength.

Also, lines can end up with slight damage over time (dragging lines on the ground, someone maybe stepping on them, etc.). I can make up a new set of lines for around $5. So, I have been replacing my lines that have lots of flights on them every couple of years. Just additional safety factor overkill for me.

                 Dan, we were using them for combat but I fly all the sport stuff with the same lines. The only failures we ever encountered was at the line guide at the tip. We would flip our lines now and then because it would fray them were it rubbed on the bushing. It didn't matter what material we used because I was also using the ceramic tip guides used on fishing rods. I love the stuff and I never EVER had a knot fail. The lines always broke where it exited the plane. Most of my  early combat planes were using nylon bushings at the tip guide. It took quite a bit to fray the lines but eventually they would.

I think I would use cable to the bell crank and exit the lead out guide just like with steel lines and then attach the other line there.  That would eliminate the wear problem.  I'm just getting my first airplane intended for those lines ready to go and that's my method.  I can also go back to the steel quickly if I wanted.

Dave

Thanks Dan, for this post.  I have been/am a huge fan of the Rutans and the wonderful addition to aviation they have made.

Wow, once shipping and all the charges have been applied, one of those Berkley hot line tools costs $40 to arrive at my UK home. Times are tight;  I shall experiment to see if a small electric soldering iron will do the job!