23-04, 09 & 10 Aileron Actuation Completed

Bellcrank to Aileron Pushrods

I related in a previous post that I had misread the manual & drilled the holes too close to the end of the tubes.

So this is the second attempt at fabricating these pushrods …

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… and as you can imagine I took great care in marking and drilling the holes!

I used a deburring bit to deepen the centre punch marks in the tubes, helping to centre the drill bit.

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Set Square method to mark the second set of holes at 90º.

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Having gained experience on drilling through tubes when making the Aileron Torque Tubes, I used the same technique for these pushrods.

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The Rod Ends again needed a bit of filing to fit into the tubes (see previous attempt).

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Having primed the inside of the tubes I stood them upright overnight.

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The manual suggests use of a hand squeezer to set the AN470AD4-11 rivets, since they easily lean over.

I don’t have a hand squeezer … hmmm?

Since I had a spare set of pushrods I was able to try out various methods to set these …

… I attempted back riveting using the C-Frame, and although acceptable I wasn’t very confident to get consistent results.

The rivets are long and my squeezer would not open up enough without using my thin-nosed yoke. But actually, with practice, I found I could very gently & slowly squeeze the rivet, adjusting the angle slightly during the squeeze as required.

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Happily the results were just fine : )

WD-1014 Aft Torque Tube Subassemblies

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The manual stipulates a NAS1149F0363P washer is installed inside the torque tube clevis arm along with the pushrod rod end bearing.

I used a wedge of wood to gently splay the clevis arm to get a washer in place … but I ended up using a thinner NAS1149F0332P washer … there was no way the thicker one would fit.

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All torqued up with the thinner NAS1149F0332P washer in place, and another NAS1149F0332P added on the outside to preserve the hardware thickness for bolt length.

CS-00013 Bellcrank to Aileron Pushrod

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I’ve been spraying the pushrods black, so to make it worth getting the spray gun out, I prepared the VA-256 Flap Pushrods and CS-00005
Stick to Torque Tube Pushrods as well.

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I find that marking the pushrod specified length on the bench, and using bolts to align the marks, makes it easy to fine tune the rod ends.

At this stage I only nip up the jam nut on one end in case the pushrod needs adjustment.

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The neutral position of the aileron is established using the W-00026 Alignment Template.

I was pleased how well the aileron and flaps aligned, and also with the straight trailing edges! : )


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The Aileron Bellcrank is adjusted into the neutral position by using the W-730 Bellcrank Jig.

This picture was taken earlier before the Wing Lower Skins had been attached.

Once again I found that the specified pushrod length worked a treat, and they were correct within half a turn on the rod ends.

I then torqued up the attachment bolts on the Aileron Bellcrank, but not at the other end since the ailerons will be removed for painting etc.

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