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Sonex 815 Build Logs
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Date: 11-18-2007
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Number of Hours: 3.00
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Manual Reference: C01
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Brief Description: Elevator long pushrod installation
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Long day with little to show for it. Started by installing the long pushrod, then held the forward part of the pushrod in place and marked where the two would overlap. Need to mark how much powdercoat to remove. Scotch brite wheel takes this off quick and easy. Marked and drilled the 3 holes in the forward pushrod 3/4" apart, starting 3/4" from the end. Put a little spacer against the spar box (to mark "full down"), pulled the elevators to full down, bolted the forward pushrod to the idler, and drilled through the forward pushrod into the long one. Did the two vertical holes, then took both pushrod parts out of the plane to do the 3rd hole. Upsized and deburred the holes.
Then spent the remainder of the time (maybe 2 1/2 hours) to get full travel on the long elevator pushrod. So of course this means the holes in the pushrods are now "lightening holes" since the final pushrod position ended up about an entire hole shorter than the original holes. No big deal. I'll do them over rotated 90 degrees around the pushrods. But all I have to show for today's work so far is a bunch of shavings under the aft end and 6 "lightening holes" at the long pushrod joint.
The addition of the pushrod was interfering with aft end structure in both the up and down directions to cause the elevator to hit neither the up nor down stop. Moved the elevator to the extremes of travel, marked where the pushrod was interfering, disassembled things, ground down the marked areas with the dremel. Did this many times. Access to where the pushrod interferes at "elevator down" is pretty bad. I had to sit up inside the 3rd to last bay (about 1 foot wide) and reach my arms into the 2nd to last bay, and grind on the arch-shaped angle part between it and the last bay. Best advice on this is to not rivet the bottom skin on until the day before the final inspection!!!
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The long pushrod.
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Accessed this from forwards. Elev's down, pushrod as high as it gets.
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Accessed this thru the hole. With a dremel in the hole you can't see much.
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