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Date:  3-4-2013
Number of Hours:  1.00
Manual Reference:  
Brief Description:  Checking elevator horn alignment

I wanted to double check the alignment of the HS this evening to be sure I didn't muss anything up.

First, I checked the alignment of the HS brackets onto which the elevators mount. I thread a string through the bracket holes and pulled it real tight. If the string is centered in the outer two brackets, it is nicely centered in all the others. Good to see!

Next, I refit the elevators and carefully aligned them and brought them into trail. Then, I carefully set up the camera to take a photo of the horn assemblies from as nearly perpendicular as possible, as seen in the pic.

Pulled the photo into the Visio as drew a set of parallel lines. The key reference lines are the white ones aligned with top and bottom of the HS rear spar, and the green ones that point across the to corresponding rivets on both elevators. these lines are parallel and seem to line up very well with the expected points on both elevators.

The red lines are references that show the lack of alignment of the horn brackets. It's not shown here, but each elevator fits beautifully onto the brackets, shows a very consistent reveal between the HS and elevator skin, and probably most telling of all, is that the counterbalance arm aligns perfectly with the HS skin ... a beautiful, consistent gap. If there was enough misalignment in the rudder install to push the elevator horns out of alignment to this degree, I'd surely see it mirror image at the outboard end of the elevator. Appears to be an elevator horn issue.

It seems that this situation is not inconsistent with others' experience. I'm waiting for the official read from the factory to see if I'm off base or not.

From Van's

"The inconsistencies you are facing is in the WD-605-L-1 PC and WD-605-R-1 PC, This will not cause any problems with the movement of the elevators. The tube welded in the WD-605 is nothing more than a spacer to go from the aileron to the center bearing and the location is irrelevant. When the two parts are built they build a run of 50 or 100 lefts and then build
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