The designer of the Acey Deucy specified a pulley size of 1-3/4" diameter for the aileron pulleys. These pulleys handle a 90 degree change in direction of the 1/8" control cable. From what I've read of Tony Bingelis, this is too small. On page 126 of his Sportplane Builder text, Tony mentions that a convention of 20 times the control cable diameter is a minimum. Based on that convention, the minimum pulley diameter would be 2.5". What's more, Tony errs on the side of smooth control movement. He suggests a 3" pulley would be better.

I would appreciate learning the knowledge of others on this matter.

Plan ref:

Image ref from my Solidworks model:

Thank you.