October 15, 2007
Aileron Bellcrank
Left and Right BellCrank angles we made a long time ago. We had already drilled a couple of alignment holes in them. There is a bronze bushing that is "press fit" in the outer most hole on each assembly; therefore these holes must be dead accurate for smooth aileron operation. 
First thing I need to do is make the two spacers that goes in-between the angles. plans say to use phenolic, but others have used scrap aluminum, so that is what I did.  The total width needs to be 1/4",  so I found two 1/8" pieces and used double sided tape to hold them together for shaping. Here the plans have full scale drawings so I just used tracing paper and glued it onto the part. This gives me a nice pattern to cut from.   
That double-sided tape is pretty strong, still holding after making the cut on the bandsaw. One spacer for the Left assemby and one for the Right assembly.  The Left and Right spacers are different, so make sure the right one goes where it needs too.
Clamped one assembly together with the spacer block in place. The drill bit in the outer hole is there to keep everything in alignmnet. Next, we will drill out the inner hole- through the spacer block, and out the other side. This is where a AN3 bolt will go to hold everything together.
Used a castle nut to semi-tighten the assembly ( a lock-nut is installed there for final assembly).  Readying myself for the critical up-drill of the two outer holes where the press-fit bushing goes. 
PERFECT HOLE..... NOT!  Actually the hole in not the bad part, it is the "lack of an edge" which is problematic.  After comparing the parts to the plans we found the mistake. When we made these parts a long time ago, I must have transcribed the "trace" an 1/8" off.  So when we cut it out, it through everything "up" 1/8" (or slightly more), causing this edge distance problem... AND, I have no more angle this size!  I will call Airparts out of KC tomorrow and order some more..... May need to shift focus to the Rear Spars, we will see.