Brief Description: Ground down pushrod hole in F-705 bulkhead.
I called Van's this morning (Monday) and talked to Gus. They knew of the problem and said it all depends on how the control column weldment was welded. They can't get them all exact to specs. He said it was allowable to make a smooth moon shaped grind into the metal strap at the bottom of the hole of no more than 1/8". The minimun clearance between the pushrod and the bottom of the hole should be at least 3/32". I used my die grinder with a burr and very slowly approached the 1/8" line that I marked. I stopped short of the line and then smoothed the ground surface with my Dremel. I finally smoothed some more with a Scotch Brite pad until I was satisfied there would be no stress risers.
I primed the raw metal using a small brush and seIf-etching primer from a spray can. I then used a mirror after reinstalling the pushrod to check for clearance since I couldn't get a measuring device under the pushrod. It looked OK to me and when the pushrod was moved back and forth there was not contact.
The mail came from Dynon with the longer bolt and spacer, therefore, I installed the servo pushrod and found it was now OK. The pushrod jam nut no longer made contact with the bellcrank.
Ground the strap at the bottom of the hole.
Mirror shows the clearance.
The longer bolt and spacer eliminated the jam nut contacting the bellcrank.
