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Mark Weitkamp CX4
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Date:  2-3-2023
Number of Hours:  6.00
Manual Reference:  
Brief Description:  mockup of aileron control pushrods in wooden dowel

As someone suggested in our online forum, I decided to mock up my entire aileron control system using wooden dowels. I made up a single-plate test of a new belcrank made according to dimensions posted in our online forum, and I want to verify those dimensions are right for my plane before I commit to actually making the new belcranks. And once the new belcranks are made, I want to double-check all the lengths before I cut my aluminum pushrods. Another new wrinkle is that because the new belcrank design displaces the forward ends of the aileron pushrods much farther inboard, the slot in the C1 and C8 ribs needs to be extended a long way. This is another very difficult cutting job, There is no way I can get a saw, or shear, or nibbler into that area. All I could do was drill a line of holes using a right-angle drill adapter, and then connect the holes with a Dremel. I started out by extending the slot by 3 inches, and when I tried to connect the pushrod, that extension was not nearly enough. I may need another 3 inches. This is causing me some concern about weakening that rib, so I will probably have to figure out how to reinforce the rib somehow. My C1 rib is going to be a real Frankenstein monster. I'm thinking that maybe once I get all the angles figured out, I may be able to do the corresponding modification on the C8 by just drilling an elongated hole right where the push rod penetrates the rib. To be determined.
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