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Zenith CruZer & Sonex Logs
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Date: 12-20-2009
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Number of Hours: 2.30
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Manual Reference: SNX-C05
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Brief Description: Finished SNX-C05 - Controls Assy
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Frustrating week with work, family arriving for Christmas, etc.
Finished the control stick assembly. This entailed drilling holes in each of the control sticks for an AN4 bolt to secure the handles to the lower control arms.
I removed the powder coating from the tube that slides thru bushing in the control stick frame (the roughly X-shaped weldment in the pic below). I didn't have paint remover, and figured that it would be quicker just to sand it off after softening with MEK.
The control arms slide thru 5/8" ID oilite bushings in the control frame. These are supposed to be pressed into place so that the control arms swivel freely yet snugly in them. The bearings were very loose in the frame - such that all rotation would be between the frame and the bushing, not between the bushing and the control arm. Kerry suggested roughing them up and then using JB Weld to hold them in place. This worked well.
Next I had to find a 5/8" reamer - no easy or inexpensive luck here. Borrowed a 5/8" drill from a neighbor and ran it thru the bushings a few times - this worked fine to hold the control arms.
The arms are then slid into the frame, and the stick handles slide onto the part of the arm that protrudes from the bushing on the front side. The handle must fit relatively tightly up against the bushing - 0.001 to 0.005" clearance. I then marked the spot for drilling, removed the assemblies, and, using the holes in the stick handles, drilled thru the control arms.
Lastly, fitted the idler arm which ties the two sticks together. This connects the lower holes of the control arms (the bottom of the triangle-shapes below) so that the sticks move in unison.
One hole is not drilled at all in order to allow for builder measurement differences. Aligned everything, clamped, and drilled - first to 3/16" then up to 5/16". Removed parts, touched-up the paint, and re-assembled.
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Control Sticks mounted (idler arm not present)
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