Title: Aileron pushtubes plus rework on spar nutplates
Talked to Vans Builder Support yesterday re; the dimension for the long aileron pushtubes. They pulled up the same drawing I was looking at and said the dimension was fuzzy on their copy as well and agreed that it looked like 66 & 6/32, but had no explanation as to why it would have changed from my 2006 vintage print, which is the same drawing revision ( rev 4). I had also put a picture of the print on VAF and somebody said that they thought it was just blurry and really was still 65 & 5/32. They pointed out that while some people had found the smaller dimension to be slightly short, adding more than an inch to it would likely make it too long to fit. Builder support had suggested that I measure the rod ends and do the arithmetic to determine how long to make the tube to achieve the overall dimension of 69 & 9/32, since it was a constant and the same no matter what source you looked at. I did that and discovered that if I made the tube to the longer dimension, the ends would be bottomed out on the jamb nuts to get the correct overall length, with no room whatsoever to adjust shorter for any potential tolerance buildup or airframe variation. This is obviously not right, so I'm inclined to think that the input from VAF is correct and that The dimension is actually 65 & 25/32 on both prints, but is sure doesn't look like it! I need one of these tubes in place so I can make sure I have clearance for the hardlines coming off the heated pitot tube, but they don't have to be cut to final length until much later in the process, so I decided to finish the tubes but leave them long, and only install the heim joint on the bell crank end, so I can get that trial fit for now. I'll get a good measurement and finish the other end during final assembly to a fuselage that doesn't exist yet. To that end, I cut the tubes to about 66.75 inches. I then cleaned the oxidation layer off of the inside with a piece of red scotchbrite on the end of a coat hangar spinning slowly in an electric drill, and plunged them with paper towels wetted in acetone shoved through with a smaller aluminum tube I had laying around. I primed the inside by taking a rubber glove over one end and spraying tempo zinc phosphate self etching primer into the other end and then sloshing it around to cover the inside. Once the outside was cleaned up similarly, I sprayed them with some new primer I picked up at Sherwin Williams this morning. According to Sherwin Williams, FA3XEP is the same thing they used to call 988GBP. When I dissected the old r/h elevator, that's the primer that was on it and it was obviously a lot tougher that the zinc phosphate so I'm giving it a try. I'm pretty sure it's also going to be quite a bit heavier and it costs $16 per can, so my plan is to use it where stuff might get beat up, but stick with the zinc for ribs and stuff like that. I'll give this a couple of days to get 100% hard and then install one of the rod ends for the trial fit I need.


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