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Bruces Web Site
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Date: 1-9-2017
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Number of Hours: 4.00
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Manual Reference:
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Brief Description: Bellcranks and aileron
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Bent the aileron bellcrank arms until they matched holes and the top and bottom were parallel. Took several itterations, but was not too bad. Decided to check out the aileron pushrod fit. Where the rod end at the bellcrank bolts to the bottom of the upper and lower pieces (not a good practice, in my opinion, the rod end should bolt between the two pieces), the rodend can be limited in up and down movement when connected to the aileron. Did some of the aileron work including nutplates on the four hinges and inserting the bearings by heating the cranks and pressing in the bearings. Put on the aileron.
Well, it works Ok, but common practice is to put an oversized washer on the side of a rod end that is not captured between its connection. Rod ends do come apart, one did on my glider, and if not captured you can lose the control. On the glider it was a captured connection with a two sided bellcrank. This limited the problem to just a lot of slop in the control that was apparent in the air. With the washer the movement is limited and will bind when the aileron is around nuetral. Will make a couple of special steel washers, that are used as spacers and do not restrict the rod end rotation and then use a slightly longer bolt and a large washer to solve all the issues.
Also noted that the aileron pushrod is about 2" to long, the third photo shows the pushrod with the crank in neutral and the pushrod extending, without a rod end, 1.5" past the bellcrank. Need to check this out more.
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