7/12/23 - 1.0h
I found a12-22-2020 update to the Aileron Actuation plans during my review of the Service Bulletins, Notifications and Letters, and Revisions and Changes for the RV-14 on the Van's website. The revision changes the procedure for aileron alignment. I downloaded the changed section from the website to update my electronic plans, which I purchased in early 2020,

There are a number of “clean-up” items I want to square away in the wings, like the final fit and installation of the pitot tube, final systems routings, and installation of the autopilot servo bracket and magnetometer mount before I install the bottom wing skins. I waited on those items to install the aileron control components to ensure I didn't inadvertently interfere with the bell cranks and push-rods for the controls. The idea was to complete the control systems and all the other miscellaneous tasks with the bottom skins off to make it easy to access the inside of the wing.

The plans start with the installation of the ailerons. I can't do the final installation until the bottom wing skins are done, so that will be added to the list of “clean-up” items for later. I plan to temporarily install the ailerons with some throw-away hardware to set up the actuation system, and then remove the ailerons at the end of this stage of the build.

The large pushrods are made from aluminum tubing that has to be primed inside and out. I've heard other builders say they had problems priming the inside of the large pushrod, and was advised to use “val-oil” instead of priming. Val Oil is not easy to find, so I'll probably give priming a try. The other thing I noticed are several holes that need to be drilled into the pushrods to accept threaded endcaps. I think free-hand drilling the curved tubing would lead to problems and disappointment, and the plans specify use of a drill press on the bellcrank-to-aileron pushrods. I don't have a drill-press to drill those holes, so I'll have to impose on a builder buddy to use his drill press. One other item to note is the hole location dimensions for the bellcrank-to-aileron pushrods is incomplete in the plans. The center of the inboard hole is 13/32” from the end, but the outboard hole distance is not specified. Fortunately, the RV-10 plans have the exact same diagram, with the outboard hole distance specified at 7/32”.

The design of the aileron control system is not overly complex - it starts with a torque tube at the wing root connected to the bellcrank in the center of the wing by a pushrod, and then another pushrod from the bellcrank to the aileron. Actually preparing and assembling the parts, however, is a bit more involved and will require following the instructions and drawings in the plans very closely. I will admit that some of the instructions after simply reading them aren't perfectly clear to me, but they should be crystal clear when I start test-fitting and adjusting the various control system components. The keys to this section appear to be accurate measurements (measure twice, cut once!); identifying parts and marking them adequately for final assembly; test-fitting, aligning, and adjusting parts as needed and/or directed; and ensuring all the hardware is installed and torqued correctly.