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Date:  7-10-2013
Number of Hours:  2.00
Manual Reference:  P01
Brief Description:  More push rod assembly

Measured the push rod length for the left side. Overall length was the same as the right side, 11.18". Cut two rods to 10.75" and assembled the tips onto the rods. I messed up two rods figuring out how to do the assembly, so still need to acquire two more rods.

I cut the rods to length using the pipe cutter method shown in the Sonex Helpfull Hints video. I used my deburring tool to countersink the ID, flattened and squared the end on the belt sander, and deburred the OD on the Scotchbrite wheel.

The method I'm using to install the tip is to place a 5/16" (or 8mm) socket into a hole drilled through a piece of wood for stability. The tip to be installed is placed in the socket. The socket supports the flange on the tip. The end of the rod is heated with a propane torch, and placed on top of the tip. Another 5/16" (or 8mm) socket is placed on the top of the fixed tip, and the rod hammered down until the new tip is seated, and no more. Too much hammering will mushroom the tube. Also need to hammer perpendicular and square to keep from deforming the tube at the new tip. Might be better to heat the rods on a hotplate since there is no real heat control with the torch.
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Installing push rod tip

Installing push rod tip

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