Project: Greg's_RV-10     -     Entry

Oct 22, 2022 6.5 23-2 thru 23-6: Aileron pushrods and bellcranks Category: 23: Aileron Actu
Cut the main pushrods to length and match drilled the pushrod ends. Primed the inside of the tube and the ends. I'll let that sit for a couple days to cure.

Cut the shorter pushrods to length. Vans sent alternate pushrods that need to be reamed to 7/16”. I had purchased a reamer from Yardstore specific for this task but as I went to ream them it was apparent that I had bought the wrong size. Ordered the right size.

Move on to the torque tubes. Match drilled and installed the ends into the powder coated torque tube ends. Searched the plans for a while trying to see how long to cut the torque tube to. A 22” tube was provided by no indication of how long to cut it. Quick search on VAF confirmed to just cut it in half. Cut it and inserted into the powder ends. Match drilled to #30 and then upsized to #12 and temporarily installed the bolts. Took everything apart and primed inside and out of all non-powder coated surfaces. Couldn't reassemble after priming and had to take the primer off the ends of the tubes. Installed the AN3 bolts and torqued.

Made a 5/16" spacer out of popsicle sticks and set the clocking and length of the torque tube assembly, careful to make a right and left. Drilled the #30's and upsized to #12s. Will have to wait for tanks to be done to final install.

Cut the big pushrod tubes to length and match drilled the ends. Primed the ends and inside the tube then rivetted together once dry.

Fabricated the aileron bellcrank spacers. Installed the nut plate to the right aileron bellcrank to accommodate the autopilot servo connection. Final drilled all the #12 holes in the bellcranks and permanently installed and torqued.

10/23: Amazon came through with my new reamer this afternoon. Made pretty quick work of small pushrods. Clamped them in the vice and let the reamer do itswork with a good bit of oil.

Drilled the #40 pilot holes in the ends of the pushrods. Then primed them. Inserted the pushrod ends and drilled to #30, cleco'd as I went. Rivets were too long for the squeezer but used the gun against the back-rivet plate and it worked well.


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