I don't like to make modifications to Vans plans, but today after trying to assemble the sticks with AN bolts and washer spacers, something had to change. Unless you have 4 hands and 20 fingers, assembly in the plane becomes almost impossible. So I went off to Les’s trusty Smithy lathe and turned some 3/4” brass bushings that would make assembly a piece of cake, and offer security for the ball bushing in the stick mounting angle. The best part is it takes out all the side play in the stick assembly and you can make the thickness exactly what it needs to be to fill the gap. This is the way to go and I will probably go back and do the same thing in the aileron hinges, i.e. two bushings instead of 4 or 5 washers and a Chinese fire drill assembly technique. I don’t blame Van for the short coming, his tolerances are very good, but there are variances in any sheet aluminum airplane and after all this is a hand built plane. In my mind, this is where the craftsmanship comes out and longevity and ease of maintenance goes in. This was fun and rewarding building today; tomorrow I will finish up the front center tunnel cover and maybe the seat back adjustment lips. I am running out of parts and will probably need to order the finishing kit soon, but I was hoping to get through the holidays before I send papa Van another check.
