Problem with short aileron push pull tube

[onex0127]

C01-05 3

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PUSH PULL 1

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as anyone run into a problem with installing the C02-05 push pull tube. If I try to install on the bottom of the bell crank paddle, I am unable to do so because it hits the spar. If I try to install on top, it works great except the bolt head scrapes the W20-05 brace. I don't see any instructions for grinding out the spar. Any thoughts?

[onex0127]

The solution I ended up with was to open the hole for the short rod. Not an easy task with the wing being skinned. If you clean up the hole as it looks like it should be, be ready to take off about 3/16 of an inch more one the inboard side bottom half. than the rod will fit.

[onex0127]

I sill need to shave just a little more on the right wing

[Don_P]

Hi Roy,

This post is a little late, as I see you solved your problem with the aileron push-rod. I experienced the same problem last year on Onex 0095, but fortunately that happened before I closed the wing. I also had to widen the hole inboard just a bit.

Hole in spar for aileron push-rod

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There is another problem related to the aileron push-rod that you might be interested in. Depending on the manufacturer of the rod-end bearing, the possibility exists of the shoulder of the bearing interfering with the bellcrank at the pivot point. Took me a while to recognize this as a problem, as it did not show up until I tightened down the nut at the interface point.

Aileron bellcrank interference with rod-end bearing

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This can be fixed by modifying the bellcrank as shown here.

Modified aileron bellcrank

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[onex28]

For those who have enlarged the spar access hole for the short aileron P/P tube, what tool and procedure did you use? I'm ready to skin the wings but better fix this first. Thanks for the answers.

David
N951X (reserved)

[Klimek]

David, On mine, I started with a very fine file, Chain saw style. then finished with a Dremel tool. I made a pattern from the first hole and copied it to the second side so both would be the same shape. Finished with some Scotch Bright.
I hope this helps. Mine turned out fine. If you didn't know you would think they were pre cut.
By the way, I'm ready to hang the engine on mine. Waiting to get all cockpit work done, including the instruments, prior to installing the inboard ribs and skins.
I'm old and stiff and need all the room I can get. Ribs have been fitted and taken back out.
Good Luck!
Frank
ONEX090

[onex28]

Thanks Frank, I'll do it that way. Also, I trial fitted my L inboard wing skin and the slots for the outer wing lift do not line up and the cutout for the wing lock witness is off by approx. 1/8 of an inch. Did you have this problem? Looks as if I have to cut and file. CNC is not always on point and I'm not going to be happy with an enlarged cutout. By the way, I'm old and stiff also after crawling around the airframe, circa 1937.

David
N951X (reserved)

[Klimek]

David, I have fitted my ribs and removed them for access to instruments and cockpit. I can stand between the spars. I don't know about the skins at this point, however,
I will find out soon. The wing fold bolts and main spar lock pins have been a nightmare for me. Thinking (not easy for me) and a lot of searching have resulted in a cure
for these two problems. Engine assembled, all instruments except altimeter are in so I only have 90% to go.
My E-mail is ...flylite@cox.net if you wish to contact me directly about mods, cures and problems.
I will be 66 on the 22nd of this month and hope to get a few years of flying my ONEX before hanging it up.
Hope to see you at a SONEX fly in some day.
Let the games begin.
Frank
ONEX090