I didn’t like how warped the elevator idler came out. The idler bracket on the torque tube is twisted. I decided to remove one of the bushings, weld shut the hole and re-drill the holes in the idler bracket. I also cut the tubing of the idler and rewelded is square, since I had originally put a twist in it to compensator the twisted bushing holes. I ended up halving to cut the idler bushing asymmetric to lineup with center.
Drilled holes in elevator idler bracket. Cut bushings then welded bushings to torque tube. Machined front plug and welded to torque tube assembly. Rear pushing came out twisted, so we’ll have to see if that winds up being a problem and needs to be fixed.
Cut out opening in the the torque for the control stick, then welded in the control stick housing and the elevator idler bracket. Afterward I drilled the holes in the control stick housing per the plans. Lastly I welded the aileron pushrod tabs onto the torque tube.
Today was one of those days. After welding together the control stick housing, I realized it was made to the wrong dimensions…I remodeled it and CAD, recut the flat patterns, then bent and welded the halves. Before leaving for the day I decided to cut the main torque tube to length. I measured three times…just used the wrong length. That piece went into the scrap bin. I flew down to spruce for a new piece and recut to the correct length.
I had to CAD model this part to make a sheet metal template. For some reason the the CAD modeled part i already had wouldn’t convert to a sheet metal part. I also had to weld up a jig to make the .75in radius bend in the parts