Elevator alignment

[Nev]

When I assembled my elevators, I first aligned the bellcranks, then match-drilled them. I later realized that the elevators were not exactly aligned due to one of the bellcranks being slightly offset by a few degrees. At the time I was able to resolve most of it during rigging, but over time I realize that this is not optimal (the issue is still present) and I would like to resolve it.

So, any ideas on how best to proceed would be gratefully accepted.

I've considered :
- cutting and re-welding one bellcrank. Probably difficult due to close proximity to the fabric.
- aligning the elevators on a bench, then re-drilling the bellcrank holes to an AN4 size. This will require ensuring that the structure is not compromised by enlarging the holes.

Thoughts ?

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[jaredyates]

I know it isn't easy due to the geography but I think you are into Bob territory when considering hole size changes on such important parts.

[Bcone1381]

I'd call Bob. I'm thinking he might advise you to close up the hole using a welding torch then redrill. But I'd call Bob before doing that.

[Nev]

Actually that's a very good idea.

[Nev]

Thanks guys - yep been trying to call Bob regarding the holes but haven't got through yet.

[whee]

I’d bet that Bob is going to suggest welding the holes and re drilling. It’s pretty straightforward and would be a good way to go for peace of mind. Be aware that the welded area will likely be pretty hard so take you time when drilling.

I’d take a look at the edge distance standards and if you can meet them with the hole drilled to the next size then I wouldn’t be worried about it. With properly torqued bolts there won’t be a shear load at the bolt to tear through the material but meeting the edge distance specs give a good backup if the bolts loosen.

[Lee]

I talked to Bob a couple of days ago and he was leaving for a few days. Try again first of the week.
Lee

[Nev]

Thanks Lee.