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Sonex 815 Build Logs
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Date:  11-14-2007
Number of Hours:  2.00
Manual Reference:  C05
Brief Description:  Control sticks installation

Drilled the sticks to the lower sticks. How to get the stick tight to the bushings? I put the upper stick in the v-block clamped to the drill press, then put the control triangle on the lower stick and held it in place to drill through. Got both sticks drilled and bolted on, and the right stick was loose. Checked that it didn't slip in drilling (the holes were round), the little tube welded onto the upper stick is just too large diameter to be snug on the lower stick. I was afraid I would just have to live with a rattling right stick. I thought this might be ok because the left stick was snug, but you could feel the rattle in the left stick through the idler pushrod. So I had to fix it. I put it in the vise and squeezed it a little until it was snug. Worked out just fine.
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Setup on the drill to keep the lower stick tight on the bushings.

Setup on the drill to keep the lower stick tight on the bushings.

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Idler pushrod in place.

Idler pushrod in place.

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Extension on each lower stick acts as a stop.

Extension on each lower stick acts as a stop.

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