Aileron setup continues like its for real. This can be close to the final setup right now.

It is time to find out if the stick hits the window at full deflection with the ailerons hooked up and in spec.

Spec is 2.1″ at the trailing aileron edge inboard +/-0.3″. The ailerons are capable of 2.5″ deflection so I spent quite a while trimming that down and finding where they are perfectly equal at neutral. I went for 2.0″

I had to fabricate a joiner between the universal and the rear stick. Yes I should have had the nuts facing down. My bad.

When I was happy with the ailerons matching AND the bell-crank at a happy place close to straight up, I fixed it in place as you see above to drill out the ‘drive tube’.

I used my drill jig to get the thing started. It took a bit of drilling as the inner part is steel rather than aluminium.

Finally drilled out, I have ailerons connected.

Here’s the stick full left which is not a problem when seated in the plane.

Full right is within .3″ of the window and there is enough slack in the system to get it to touch the window. I am going to need some hard stops on the pilot seat edge to prevent this. I will play with the angles a little more first to see if I can get the stick a little further away  by adjusting the midpoint inwards.

Meanwhile I had a look in the wing root and I am NOT happy with bolts upside down. If a nut failed the bolt would drop out. That said metal lock nuts generally don’t fail. Its more about good practice. Mind you this orientation here is exactly what the plans tell you to do.

I have swapped out with an AN4-10A and reversed it to the ‘correct’ way around. I needed the longer bolt so that ALL of the shank is in the bell-crank. This is why the plans have it reversed. I found I could get the desired result AND have the bolt correctly orientated. It did leave a few extra threads past the nut. I know this is OK because I checked where the shank went to. So we are good?

OK I can see the other bolt is the wrong way around. In this case there is not room to turn it. So I have to live with that one.

After many many hours setting up the ailerons I found a lot of slack in the system. One place was at this Igus bearing. There is a long run to the front seat from here and it had some play laterally.

My solution was to put another bearing on the opposite side so the inner steel had more longitudinal support. This took many hours to fit (like more than 6!) and was a minor improvement. Worth doing. Getting slack out of the system is all about chasing down the small things.