5/21/2006
Today I put in the electric aileron trim mechanism. First I fabricated the aluminum pushrod as per the plans. This entailed cutting it to size, cutting a slot in one end and drilling three 1/8" holes. I used a band saw with a v-shaped holder to do the slot. I cleaned it up with a file, Scotchbrite wheel and sandpaper.
Using an aluminum sheet template that Vans provides, I marked a rectangle on the right middle floor rib and then drilled at the four corners. The I cut between the holes using my Dremel tool with a cutoff wheel. Then using a file I smoothed it out and then I sanded it with 200 grit sand paper. Then I mounted, drilled, deburred and pop riveted the structure you see at the top right. I then marked the rectangle on the left rib and while the template was in place I drilled the holes in the template. Then I cut the rectangle using the same method.
I final drilled and countersunk the holes for the servo motor attach nutplates. I riveted them on and then screwed in the servomotor. Then I riveted the the assembly in place as shown above bottom left.
Then I reinstalled the control rod, floors etc. Then I installed the pushrod, attached it to the servomotor and then attached the springs. Voala!
Moving the control rod from side to side causes spring noises like an old bed. It is late. I will take a look at it tomorrow.