In other words here is the order-- bolt head,washer, >control horn, 2 washers, Large washer, castle nut with cotter pin. That >puts a total of 4 washers in this system. I could replace the 2 washers >with a aluminum spacer but that dose not seem practical to me. I know >others have had to do something at these points to get the geometry to >work. I just don't want to be rebuilding in front of an inspector >Joe Horton ++++++++++++++++++++++++++++++++++++++++++++++++++++++++
In my humble opinion, when circumstances dictate, let common sense prevail. I used a thick wall nylon spacer between my aileron horn and the rodend bearing on the aileron pushrod to get the correct geometry. The forces at that point are not great but you MUST have a system that has zero slop or endplay to eliminate the posibility of flutter and control sloppiness. Check for correct maximum deflection, and eliminate any binding or slop. The accepted procedure for bolt alignment on aircraft is head up or to the front of the aircraft but there are times when that's not possible and a bolt is inserted from the bottom or rear. Sometimes you gotta do what you gotta do. If your inspector gives you any hassle on that point, and I doubt that he/she will, make them give you their opinion on exactly how it should be done to be acceptable. Don't let them get by with " well I'm not sure but you'll have to change it". I really don't think you have anything to worry about. Larry Flesner
