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Date: 10-13-2025
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Number of Hours: 5.00
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Short Description: modifying aileron control horns
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Well, another day of mostly frustration. I tried to get a bit more systematic by preparing a log sheet to record starting deflections, adjustments made, and results. But after a couple rounds of that, I noticed that my belcranks were not contacting the aileron stops built into the belcrank mounting assembly, so something else was preventing the ailerons from achieving the downward deflections they needed. After searching for awhile I found that the problem was the push-pull rods were hitting the front edge of the aileron, just in front of the control horns. This prevented the belcranks from hitting their stops according to the design. I had been planning to try a new approach, which was to set each belcrank at its stop position, and adjust the corresponding aileron to 15 degrees down. but this control rod interference prevented that, and I spent the rest of the day trying to eliminate that interference. I figured that I needed to modify the aileron control horns to provide more clearance between the rod and the aileron front edge. I wasn't really sure exactly how, so I wanted to set up a way of trying different positions using scrap pieces clamped to the existing horns. But this failed, and I ended up removing the horns from the right aileron and making new ones, just increasing the 5/8 inch offset from the aileron surface to 7/8 inch. I'll have to make the same change on the left aileron before I know whether or not this is going to work. That will be tomorrow's task
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