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Date:  1-1-2009
Number of Hours:  0.00
Manual Reference:  
Brief Description:  Aileron - Drill aileron push tube.

First image is the final picture of the stick push tubes.
The next 2 images deal with the smaller diameter aleron push tubes.

The aileron push tube is steel, not aluminum. Again I used the same 3 bit process to drill the holes in steps. Starting with 1/16" bit, then #40 and finally the #30. You drill 2 purpendicular holes. The question. How far from the ends of the push tube do you drill the holes.

The theaded push tube end that fits inside the tube is about 20/32".
So 20/32" divided by 3 is about 6.5/32".
First hole is 6.5/32" from the tube end and the second hole is 13/32" from the end.

I measured the 6.5/32" from the end and drilled it first. Again using the clamp system in image 2. I used the auto punch 4 times to get a good center punch. I used a bunch of Boe Lube and drilled completely through the tube getting 2 holes at once. Major deburring on the exit hole.

The second hole is 90 degrees from the first. I measured 13/32" from the end and made a mark in the general area of 90 degrees frim the first hole. Placed the tube in the drill press clamp and using the small drill bit I cut through the blue tape just enough to make a mark. To get this mark 90 degress from the first I put my pointy thing through the first hole so that I could see that it was parallel to the bench press table. After making the mark I removed the tube and used my auto punch 4 times where the bit scored the blue tape. Put it back in the drill press clamp and drilled away with the 3 bits.
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Stick push tube riveted.

Stick push tube riveted.

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Aileron push tube gets drilled.

Aileron push tube gets drilled.

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Pointy thing helps to get purpendicular holes.

Pointy thing helps to get purpendicular holes.

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