SonexBuilders.net

Hi guys,

I attached my ruddervator pushrods to the control mixer last night, and I noticed that with the pushrods installed and routed out the slots in the aft fuselage side panels, they're angled upwards enough that the rod end bearings run out of angular travel before the mixer hits the aft stop. Has anyone else run into this?

I tried stacking a couple washers between the rod end and the top of the plate of the mixer to give it some clearance, but it still isn't quite enough. The mixer is about 1/2" short of the aft stop (i.e., elevator full up control) and the rod end just can't accomodate any more deflection.

My only other thought is to maybe replace the washers with a spacer which would have a smaller OD than the washers to maybe buy a little more space, but I'm not sure if even that would work!

Here are a couple pictures of what I'm working with:

Any chance the interference is from the fender washers contacting the rod end? I've test-fitted my rods/mixer/ruddervators and had no issues...but I hadn't installed the retainers/fender washers yet.

My recollection is I was close on the mixer weldment but definitely hitting the washer. I pressed a cup shape into my washers and was good. Shoot me an email and I'll forward an email I sent out on the topic. My Gmail address is my first name, last name, and serial number all jammed together.

Also I had a similar issue on my tailwheel steering. I used two crescent wrenches, one metric and one SAE, to put a little twist in the steel part. This would work here as well.

Oh good point on the fender washer... maybe that's actually what's interfering. I'll go check!

What is the purpose of the big fender washer anyway?

Bryan I just emailed you at your name and then 191... hopefully you meant that and not the full tail number. Thanks!!

Oh yeah, it's totally just the fender washer that interferes. Duh. Well this is much simpler than I initially thought!

Thanks guys!

The fender washer protects you against a failure of the rod end. If it gets worn enough for the eye to pop off the ball, the fender washer prevents it from coming all the way off. You still have control, just some extra slop to get your attention.

Oh yeah good point! Anyway I squashed my washers into a dome shape and now everything fits!!

I’m coming up on this step....how do you Squash a washer into a dome???

Gordon

The cupped washers are created by chucking a short bolt into the washer with a nut to hold it tight. Then get a socket of a suitable size to line up with the OD of the washer. Use an arbor press or vise to squeeze the washer between the bolt head and socket.

Cool. Thanks