I started out today by drilling the holes in the sticks for the 3/8ths bushing. This is the pivot point for the aileron control and I wanted a nice, tight, smooth fit for the bolt. Instead of the .058 tubing spec’d for the busing I used .065 and ran a .250 reamer through the bushing. The bolts slip in smooth with no play and it pivots like it’s on bearings. From now on whenever the plans call for a .058 bushing for an AN4 bolt, I’ll use .065 and ream to size. The fit is phenomenal.
I also drilled the AN3 bolt for the removable co-pilot stick. Bob said an AN3 would be just fine. This will allow for two things. If it ever gets loose, I can always go to an AN4, or add a second AN3 bolt. I also relieved the top of the channel the stick pivots in. Two BH builders, Ron Jones and Rob Taylor experienced limited travel in the ailerons while rigging. They found the stick was actually hitting the top of the channel. So I relieved the top part a bit so I wouldn’t have that problem. Pat Fagan also added adjustable stops to the aileron axis near the bottom of the stick assembly and I’ll probably do the same. Once it was all together, it really looked cool and was even and smooth…on to the brackets.
