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Cowboy's RV-10
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Date:  2-14-2010
Number of Hours:  7.00
Manual Reference:  11-6 / 11-8 / 11-9
Brief Description:  Pushrod Assy / Trim Servo Installation

11-6:
Step4: Reinstalled Vertical and Hz Stabilizer hardware that was recently primed. Began to assemble the Pushrod and threaded ends only to find too tight with heavy primer inside from slosh and drain technique suggested in the plan. Lightly sanded primer off of mating surfaces and pollished the threaded rod ends with buffing wheel to give a little more clearance. Then reshot a light coat of primer on just the ends of the assembly.

11-8:
Step 8: Fitted the Trim Bellcrank Brackets with the trim bellcrank in place to work out the clearances and fit as necessary. I found the Bellcrank Bracket spacers (nylon I think) so thick that I could not get the Bellcrank AN-4 bolt in as it interfered with the 470AN4 rivet heads. I considered other thinner material but did not have anything suitable so elected to slice the nylon spacer in half using the bandsaw and a wooden guide with two sided carpet tape. Surprisingly, it works out quite well and the spacers were reduce in half and clearance with the AN-4 bolt was just enough to get in through the bracket holes. Now is when I began to rivet it all together to include the Trim Bellcrank Brackets, Trim Servo Spacer, Trim Cable Anchor Brackets and four nut plates (just realized I need to rivet the close-out flanges). Interestingly, after all that work to align the Trim Bellcrank Brackets seven ways to sundown, I found the clearances for the .032 in AN960-416L washers WAY TOO TIGHT after riveting. The two washers together are .064 in. I had only room for .040. So I took some two sided carpet tape on a half inch square stick and filed the washer down first using the belt sander, cooling with water often as I went as the temp melted the glue on the two-sided tape, and finishing up using a flat file and honing stone. End state was approximatley .018 in for each washer which once assembles requried just a slight pull-down of the AN-4 bolt to take up minimum slack. What a bunch of work this was.

11-9:
Step 1, 2, 3, 4 completed (stupid kitlog truncates after so much text)
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Slicing Trim Bellcrank Bracket Spacer in half

Slicing Trim Bellcrank Bracket Spacer in half

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Top of Trim Servo Assembly

Top of Trim Servo Assembly

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Bottom of Trim Servo Assembly

Bottom of Trim Servo Assembly

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