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Date:  7-4-2013
Number of Hours:  2.00
Manual Reference:  
Brief Description:  Aileron Push Rods

I cut my aileron pushrods to length. I carefully measured the longer rods at 65 and 25/32" and put a pipe clamp on the tube to guide the saw blade and keep it square (idea obtained from Stacey David's Gearz show). The clamp worked great, but somehow I managed to get one tube slightly shorter than the other anyway despite having measured them repeatedly. I cut the smaller rods with a hacksaw as well, although in hindsight I should have used my pipe cutter as it would have been faster and easier.

I cleaned the cuts with a deburring tool and a pass on the Scotchbrite wheel and taped off one end of each tube. I poured primer in the tubes and rotated them to get even coverage before dumping the excess primer.

I drilled the shorter tubes on my drillpress, which didn't come out perfectly but I sent pictures to my tech counselor and he said they will be ok and to build on. He suggested backriveting the rod ends since my pneumatic squeezer is not expected back from Avery Tools until Monday.

I had sent the squeezer back to Avery for repair last week even though it was out of warranty. I sent a note asking him to let me know how much I owed for the repair. Mr. Avery said that an O-ring had split and that is what caused the malfunction. He replaced two O-rings, lubed the squeezer and sent it back at no charge. He would not accept any payment so I made a small donation to Give Kids the World in his honor. I highly recommend Avery Tools for any tool purchases! I ordered a set of washer wrenches, a rod bearing adjustment tool (I split the PVC tool I made previously) and more torque seal.

I also ordered a Whelen HD60 installation kit for my strobes from Aircraft Spruce. Everything should arrive sometime next week.
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Clamp on Tube to Guide Cut

Clamp on Tube to Guide Cut

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