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Kurt Haller RV-9A
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Date:  7-14-2007
Number of Hours:  2.00
Manual Reference:  7
Brief Description:  Aileron pushrods; flap brackets

Finished drilling holes for the long aileron pushrods. Then drilled all holes out to #30. Marked the cones and pushrods so the cones could go back in same orientation then pulled cones and deburred everything.

When I press fit the flap bushings into the brackets, they were flush on one side and proud on the other.

Made a hardwood "washer" shown in Image 1. Used a 1.5" Forstner bit to level a big area, then a 0.5" Forstner to go about 1/32" deeper, then drilled out for AN4 bolt. Used a chisel to give the big area a "U" shape. If the depth of the 1/2" area was exactly 1/64", could tighten up the bolt on on the proud side and the flush side would pop out to the proper overhang.

But it wasn't hard to jockey the bushing back a forth to get even overhang (fingers are pretty good judges) on both sides.
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Wood

Wood "washer"

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Bolt/washer on proud side

Bolt/washer on proud side

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Wrenches ready to set the bushing

Wrenches ready to set the bushing

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