So I got everything mounted in place, made the elevator cables and properly tensioned them to 25 lbs.
I gotta say I'm pleased with the way this came out. It operates perfectly, is very strong and rotates super smooth. On either side of the aluminum tubes that holds the horn in place I added oilite thrust washers because these two tubes may or may not rotate, so I wanted it to be smooth. The shaft does not rotate and is locked into place from either side with 8-32 screws (I threaded each end of the shaft). It all fits nicely with no interference from the torque tube. The joggles in the horn keep the cables separated in the middle of the fuselage. You can see I also clecoed in the new torque tube anchor and the cross member that spans the bottom hatch...wanted to make sure everything was free and clear and it is.
I plan to re-route the rudder cables over the top of the rectangular aluminum extrusions...it will actually be a straighter line to the rudder.
Lastly...the weight....the hunk of steel I cut off the torque tube and the original aluminum horn weighed in at 11 ounces. The parts I added were 20 ounces...so a net weight gain of 9 ounces. Pretty good.
