I ordered a solid 3/4" OD rod of Delrin hard nylon from Aircraft Spruce. I then traced the drawing of the aileron installation which was full scale (Dwg 13A) to get the postion of the aileron attach bracket pivot point on the hinge bracket. The other end of the attach bracket is the pushrod attachment point. I then rotated the tracing 32 degrees (max up aileron deflection). I traced the hinge bracket to see where the pushrod end would be relative to the hinge bracket. The pushrod attach point was short of touching the hinge bracket. I took a compass and drew a circle to just touch the hinge bracket and it gave a 0.550" diameter which will be the OD of the nylon bushing. The aluminum spacer bushing for attaching the pushrod is 3/16" ID x 5/16" OD x 3/8" long.
I cut off a piece of the nylon rod 3/8" long and then center drilled a hole that was 5/16" diameter. The nylon bushing was pressed onto the aluminum bushing using a 3/16" bolt, a couple of flat wahers and nut. While clamped onto the bolt between the washers, I put the bolt into the drill press and then used a file to reduce the 3/4" OD down to the 0.550" OD that I had drawn.
I installed the ailerons and inserted the fabricated bushings while connecting the pushrods with the AN3 bolts to the aileron attach bracket. Using a digital level, I checked the deflection angles from the neutral position. I measured about 29 degrees when the bushings contacted (i.e. "stopped") on the hinge bracket. I wanted to be closer to the 32 degree max, so I removed the bushings and turned them down to 0.544" OD. After reinstalling the deflection angles were 30.8 - 30.9 degrees for both ailerons. That was close enough for me. After final assembly there might need to be more adjustments, but it will be easy to do!
For information purposes, the up deflection angle is max 32 / min 25 degrees. The down deflection angle is max 17 / min 15 degrees. The down deflections can only be measured when all the controls are fully installed.
