Brief Description: Loosely Install Main Aileron Pushrods and Adjust
I left the plywood jig clamped to the left wing. This kept the left aileron locked in the neutral position as well as the left bellcrank now that the short pushrod from the aileron to the bellcrank is installed.
Next I moved the W-730 bellcrank jig from the left wing to the right wing. This locked the right wing bellcrank into the neutral position.
Then I set the control sticks to their neutral vertical positions and fed the two main pushrods through the lightening holes from the outboard ends of each wing and adjusted the rod end bearings until both ends were centered and had the same number of threads showing and until I could slide a bolt into each end to connect the bellcranks to the contol sticks.
With the left aileron locked in place by the plywood jig and with the right wing bellcrank locked in place by the W-730 jig, and with all the pushrods in between these points in place, the sticks could move fore and aft but not left or right.
My next task was to rotate the main pushrods until they bottomed out on the rod end bearings one end to make sure they would not unthread and drop out of the rod end bearings on the other end. Unfortunately, this test failed and the pushrods pulled out of one rod end bearing before bottoming out on the other. The main pushrods are about 1/8" too short. Damn.
After reading about this problem on other builders websites there is an easy fix. As long as there are enough threads engaged on each rod end bearing you can install a second jam nut on each end which will take up the excess threads such that the pushrods can't back out of one rod end bearing before bottoming out on the other end and preventing the pushrods from disconnecting.
Left pushrod loosely connected between left stick and bellcrank
Right pushrod loosely connected between right stick and bellcrank
Right bellcrank locked into position with W-730 aluminum jig and pushrods loosely installed
