(12) Controls ( Mike )

[planecrazzzy]

Hey Guys,
                I've got the bellcranks mounted...as of now they are spaced out from the weld with a "tube sleeve"
it's a 1/4" long , it's a better surface...
 
  I've made the Linkage to go from the Aileron horn to the Bellcranks... They are 11" center to center ( Heim )
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  I drew out the wing aileron control horn , and figured the travel needed for it....

I clamped a piece of cardboard behind the bellcrank , and marked where it should stop in both directions...
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                                   Gotta Fly...
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[planecrazzzy]

Here's a modification I made for the Aileron "Stops"

I just didn't like the "Stock" one.... I think mine is lighter... and out of the way...

I cut a piece of tubing to make them.... Then stacked a little piece on the end for

a higher/taller stopping surface....

To get them in the "exact" spot....  I clamped the piece on the tube with the surfaces "touching"....

Then , pulled the stick over while watching the bellcrank against the cardboard....

and stopped when the hole got over my mark....  Then "tacked" the stop to the control tube....

And I did the same for the otherside....

Two things.... One, the surfaces match perfectly that way.....two , it's easy to set the limit that way....

[planecrazzzy]

Hey Guys,
                 OK,  I changed this around and used the Tailwind prints AND the Buttercup prints....

I liked the lighter tube in the Tailwind prints.... I liked the Bushing support in the middle ( BC prints )

and I think the sleeves over the torque tube were mine.... Just for added strenght , since I went with

the thinner wall tube ( 1" X .035 ).... The sleeves were 1-1/8" X .058 .....

End "inserts" in the torque tube were 7/8" X .049 ...
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The Biggest improvement I like.... it can be removed.....

   OK... I have a few pictures... So I'll explain things as they are posted....

[planecrazzzy]

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[planecrazzzy]

This piece seems important to me.... although, it's not in the Tailwind prints...

The Flaps will need a lot of pressure to apply... ( I made the handle 3" longer because of that )

So this Flap Torque Tube will be getting a lot of force applied in the center....

This bushing should carry the load just fine....

I had to modifiy it so the Torque tube could come out....

Also... I put two "punch marks" on the same ends of the cap and the main piece...

Just in case they aren't perfectly symmetrical...

That's always handy to do.... these things get taken all apart.... painted and whatever...
If they aren't marked good.... it can be a puzzle putting them back together even though they
"FIT" at one time....

That's yer "Tip" fer the Day....
                                                      Gotta Fly...
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[planecrazzzy]

OK, the Horns call for "Finger Patches"....  This is "my" version....

I "sleeve" the tube  with a bigger heavy wall tube.... and cut it so it distributes the stress.

I weld it completely....

Then ,  I put extra weld passes in the front and back ...
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These had to be made and slid up the tube from the bottom.....

I welded the main tube/horn.... Then slid the reinforcing sleeve into position....
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[planecrazzzy]

Hey Guys,
               The Buttercup prints doesn't show it needs this "Side" extention.... But "mine" needs it....

( The Tailwind prints shows it needs it )

  Anywho,
               I stopped working on this earlier , until I got the Aileron linkage done in this area....

Now , I can tell how much room I need for my Flap control "rod".....

 Because I needed to extend it out so far.... I put a "bushing" in the Base mount....

This will help support the bolt better...
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.                                                            Gotta Fly...
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[planecrazzzy]

I drew out the Control horn for the wing Flap tube.... Figured out the degrees for
grinding the holes in the "Hoop"....
I used a little "ball" die grinding carbide bit.... worked great.

I used the marks on the paper to show me the location....
When you do this.... Be sure to put "flap pressure" on the linkage....
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When I was making the "splice" in the "Hoop".... I figured the head of the
3/16" bolt would end up being the Limit ( 35 degrees )
I missed it by 1/8"......  I made a little cover/sleeve that gets bolted there....( not shown )
Now.... the last flap adjustment has a "stop" ( perfect fit )
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                                   Gotta Fly...
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[planecrazzzy]

Hey Guys,
               Here's the Aileron and Flap Horns.... These are the ones attached on the Wings...
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. I put some re enforcing on the Flap Horns....

                            Gotta Fly...
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[planecrazzzy]

Hey Guys,
                This is a little different from the print...

 But it's simple , and Light...

 I used a thinner wall bushing..... and added silicone bronze inside for better "wear"
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                    Gotta Fly...
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[planecrazzzy]

Hey Guys,
                I'm making the Rudder Assy....  But I'm modifying it...

I want to be able to take it apart....  So far , it's working pretty good...
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                           Gotta Fly...
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[planecrazzzy]

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[planecrazzzy]

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[planecrazzzy]

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[ElliotW]

Mike- I would like to say that your craftsmanship is A+. I was hoping you could explain how you fabricated your Flap Control horns with the flange around the base and  continuing along the lever side?  Form press? Also concerning your TIG setup. What setup has worked best for you with your Wittman build? Cup size/electrode to have access to the real difficult clusters? Tig Braze setup? Thanks for the build log its a great help to see how fabrication is done with top notch craftsmanship.

Elliot W.