Title: Aileron pushrod tubes
A couple of years ago, I started fabricating the big aileron pushrods. The dimensions for the tube length on the preview print and the electronic version were blurry, so I started poking around on VAF. That lead me to a series of posts where people had reported making these to print length and they came up too short. I called Vans and went down a rabbit hole of trying to guess what the tube length was supposed to be based on a blurry number and thinking maybe there was a drawing revision that changed it. Ultimately, I think that I was just seeing a blurry "5" and thinking it was a "6" of maybe it was the other way around. At any rate, I only finished one end of these at that time, left the other end long, and put them up on the shelf. Now that I have the wings on, it was time to finish these up. I installed one of these tubes, pinned it to the stick weldment, and set the sticks to neutral by measuring from each stick to the corresponding side of the fuselage. I then set the aileron bell crank to neutral with the aileron rigging tool. I had put a sharpie mark on the tube at 65 25/32" which is the length Vans calls out for the tube. I measured from that mark to the appropriate bolt hole on the aileron bell crank and then measured the socket that gets riveted in the end of the tube including the heim joint that I screwed into it until just a couple of threads were showing. All that fancy measuring revealed that I needed to add about 3/8" to the length of the tube or I was going to have to unscrew those heim joints quite a bit to get the appropriate length. Standard practice with a heim bearing is to set it up so that more than 1/2 of the threads are engaged. That way if the jamb nuts come loose and the tube starts unscrewing itself it will bottom out on one end before it unscrews itself completely on the other end. I measured the other side and got the same results, so I cut both tubes 3/8" longer than print and finished them by riveting in the sockets and screwing in the Heim bearings. Installed and rigged everything and confirmed that I have 2 or 3 threads max showing above the jamb nuts on the heim joints on both ends of both tubes. Nice!


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