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Eric Seber - Waiex Project
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Date:  1-11-2014
Number of Hours:  2.00
Manual Reference:  WIX-C02
Brief Description:  Prepring & Reaming Control Tree Bushings

Well, today was slightly productive...but not really. After trying to sand the control stick assembly bushings with sandpaper wrapped around a steel rod, I decided there had to be a better way. I got out my dremel tool and tried using the sanding drum inside the bushings. The drum was just the right size to fit into the 5/8" ID bushings to remove the proper amount of material. After a few passes on each bushing half, the control horns fit perfectly. No slop and it saved a lot of time compared to using the sandpaper and rod method.

On the not so productive side, I started assembling the mixer parts. I clamped everthing together squarely in my vice and squared/secured the movable mixer arms with bungies and a scrap piece of angle aluminum. I piloted the top of the assembly with a #30 bit and they upsized to a #11 (3/16"). Next I chucked the taper reamer into my cordless drill and started reaming material. I got a little too motivated to make the hol...and oversized it! the taper pin, when inserted, went flush on the large diameter end. Not what you want.

I considered oversizing with a 1/4" taper pin, but by the time I order a larger pin and reamer I'd be close to the same cost. Also, the tubing diameter is not large, so going oversize would not be the best idea. Since it is part of the flight control system I decided to order a new pivot arm and shaft from Sonex. Lesson learned, go slowly with a brand new sharp reamer and do several test fitings before going full size.
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Used Dremel Sanding Drum

Used Dremel Sanding Drum

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Mixer Clapmed & Secured

Mixer Clapmed & Secured

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Pilot Drilled Mixer Output Arm & Shaft

Pilot Drilled Mixer Output Arm & Shaft

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