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Serenity
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Date: 8-22-2007
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Number of Hours: 1.50
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Manual Reference:
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Brief Description: Aileron pushtubes
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Started aileron pushrods/tubes. There is a long one 1 1/4" dia that runs from fuselage joystick to outer wing bellcrank, then the short one from the bellcrank to the aileron. Today, I assemble the latter. Parts needed shown in Fig 1 - first step was to cut tube to length with a hacksaw (I cut slightly oversize after reading accounts that the tubes per plans were a little two short). I then placed threaded rod end in tube and drill two holes (tube held in V-notched wood block while drilled with press). The -12 length rivets called out by Van's were a little long per the standards (and I corroborated this online, as noted by many builders), so I sanded the rivets down a little to an 11-11.5, deburred, and set. A rivet squeezer won't reach this length - research shows some people hammering, using a vice (tried - didn't like), a rivet gun, C-frame, and local builder Chad Jensen's suggestion with the DRDT-2. I did the latter with excellent result - one caveat, though - you must not crank down too much force or risk breaking the DRDT's head, so I rocked the tube a little while squeezing, which helped form the shop head. Note that I used a cup set both sides - this allowed for a nice rounded shop head, which was suggested by a builder or two to avoid interference when the pushrod exits the rear spar. Assembled rod, then adjusted to length per the plans (further adjustment when placed on wing).
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