With it being too cold to work in the shop the last week or so, I had time to contemplate how the flaperons were rigged relative to the wings and I didn't like it. So I ordered a small plate of .125 6061 T6 from Grainger and designed a new bellcrank which would allow the angle of the flaperons to be lower to compensate for the fit issues I mentioned earlier. Basically, I just lowered the location of the hole that attaches to the vertical control rod, which lowers the aft end of the flaperon in all control positions. Fabricated the new part (what appears to be blast marks in the photo is just reflection from the scotchbrite deburring). Reconnected using the new bellcranks and evaluated the results. Initially, it all looked and operated perfectly until I checked the travel with flaps down. With the flaps down, roll control was severly limited by the range of the control slot bottom. After some more filing and much control rod and flaps actuator rod adjusting, I got the specified travel in all flaps settings.
