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10/30/2006

Well, with all the surfaces complete on the wings, it's time to work on the control pushrods that connect the ailerons to the sticks.  I started by cutting the two tubes that will make the W-716 and W-818 push-pull tubes.

Since these were rough cuts with the hacksaw, I had to fine tune them to specific lengths.  The short tubes are cut to 23 13/16" and the long tubes are cut to 65 25/32".  Here's the short ones after they were finished and smoothed.

Next is to prime the INSIDE of the tubes.  This is the first time I can recall in the plans that Van's says they are to be primed.  Usually it's an option if the builder wants to.  I did as they said, used the 7220 and sprayed it down each tube, and spinning them as I sprayed to get good coverage.  When those were dry enough, I inserted the AN490 HT8P rod ends in the short tubes to be drilled.  I marked the end of the rod end, and both rivet locations.  The rivets will be 90 degrees from one another.

I bought that little V jig called the "Center It" tool.  It works great!!  After those were drilled and deburred, it's time to set the rivets.  This sucks.  I tried the pneumatic squeezer, and there is not enough travel for the 4-12 rivets to be set.  I didn't really want to try and whack the rivets in the regular C frame tool because it's really hard to control.  I decided to try the DRDT-2 dimpler.  This actually works out ok.  I sorta used the handle as a hammer to get it started, then tapped the rivet until I got the result I wanted.  The shop heads are curved because I wanted as much surface area from the shop head and the manufactured head to contact the rod as I could get.  They aren't the prettiest looking shop heads, but it'll work well.

The rod slipped off the dimpler a few times, and marred the powdercoating, so I decided to prime each end after masking the threads off.

Short ones are done, and tomorrow I'll do the long ones.

3.5 hours