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Aileron Bellcrank Bushing Questions

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kearney(at)shaw.ca
Guest

Posted: Sun Jun 29, 2008 5:21 pm Post subject: Aileron Bellcrank Bushing Questions

Hi  

   

I was working on my wings today and tripped over a couple of small issues.  

   

When filing the bellcrank bushings down to the required length, I made them slightly undersize (2.745” rather than 2.750”). Is this going to be an issue given that I am required to file the bellcrank tube to ensure at least 1/32 – 1/16” of the bushing is exposed?  

   

As well, I need to ream the bushings so that an AN4 bolt will fit inside. Reaming is new to me so I would like a little guidance as to how to ream these bushings. What do I use to ream them?    

   

Inquiring minds need to know  

   

Les Kearney  

#40643   

       [quote][b]

Tim Olson

Joined: 25 Jan 2007
Posts: 2872

Posted: Sun Jun 29, 2008 5:45 pm Post subject: Aileron Bellcrank Bushing Questions

Les Kearney wrote:

 	  Quote: 	
		   Hi

 

  

 

 I was working on my wings today and tripped over a couple of small issues.

 

  

 

 When filing the bellcrank bushings down to the required length, I made 

 them slightly undersize (2.745” rather than 2.750”). Is this going to be 

 an issue given that I am required to file the bellcrank tube to ensure 

 at least 1/32 – 1/16” of the bushing is exposed?


	


Probably not an issue.

 	  Quote: 	
		   

 As well, I need to ream the bushings so that an AN4 bolt will fit 

 inside. Reaming is new to me so I would like a little guidance as to how 

 to ream these bushings. What do I use to ream them?  

 

  


	


You should use a reamer.  Just check out a local machine tool

place...they can sell you reamers.  Just turn them like a drill

bit only slower as it goes through. Makes a nice clean hole.



Tim Olson - RV-10 N104CD - Flying

do not archive

 	  Quote: 	
		   

 Inquiring minds need to know

 

  

 

 Les Kearney

 

 #40643

orchidman

Joined: 10 Jul 2006
Posts: 277
Location: Oklahoma City - KRCE

Posted: Sun Jun 29, 2008 5:56 pm Post subject: Re: Aileron Bellcrank Bushing Questions

In my opinion, reamers are an essential tool.  I have all but worn out a #40 and a #30 reamer.  All my match drilling was done with one of these.

To find out a little more about reamers, go to page 34 of the avery tools catalog.

http://www.averytools.com/catalog/2008%20catalog%20B.qxd.pdf

then scrole down to page 34.  There is some good information about reamers and how to use them.  Since our skins are so thin, I never used any lubricant.  If I were reaming anything thicker then the diameter of the reamer, then I sure would use a lubricant.



Off the top of my head, I don't remember what I used for the bellcrank but since I don't have a 1/4" reamer, it must have been a sharp 1/4 drill.

_________________
Gary Blankenbiller
RV10 - # 40674
(N2GB Flying)

jesse(at)saintaviation.co
Guest

Posted: Sun Jun 29, 2008 5:56 pm Post subject: Aileron Bellcrank Bushing Questions

I can't answer the first question, but the easiest way, by far, to ream the bushing is to track down a lathe and chuck up the bushing and run a 1/4" reamer through it.  That way it is perfectly centered and controlled the whole way.  I don't understand why Van's doesn't do this for us, since it is one of those steps that seems like it would be much easier to have them do than to have us find a lathe.



do not archive



 Jesse Saint

Saint Aviation, Inc.

jesse(at)saintaviation.com (jesse(at)saintaviation.com)

Cell: 352-427-0285

Fax: 815-377-3694



 



On Jun 29, 2008, at 9:17 PM, Les Kearney wrote:

 	  Quote: 	
		  Hi

 

I was working on my wings today and tripped over a couple of small issues.

 

When filing the bellcrank bushings down to the required length, I made them slightly undersize (2.745” rather than 2.750”). Is this going to be an issue given that I am required to file the bellcrank tube to ensure at least 1/32 – 1/16” of the bushing is exposed?

 

As well, I need to ream the bushings so that an AN4 bolt will fit inside. Reaming is new to me so I would like a little guidance as to how to ream these bushings. What do I use to ream them?  

 

Inquiring minds need to know

 

Les Kearney

#40643



 	  Quote: 	
		  http://www.matronics.com/Navigator?RV10-List

blue; text-decoration: underline; ">http://forums.matronics.com

style="color: blue; text-decoration: underline; ">http://www.matronics.com/contribution



	


	


 [quote][b]

Kelly McMullen

Joined: 16 Apr 2008
Posts: 1188
Location: Sun Lakes AZ

Posted: Sun Jun 29, 2008 6:49 pm Post subject: Aileron Bellcrank Bushing Questions

Do you use the reamers in your air drill, or in a slower speed

cordless drill? Any thoughts as to whether it matters?



On Sun, Jun 29, 2008 at 6:56 PM, orchidman <gary(at)wingscc.com> wrote:

 	  Quote: 	
		   



 In my opinion, reamers are an essential tool.  I have all but worn out a #40 and a #30 reamer.  All my match drilling was done with one of these.

 To find out a little more about reamers, go to page 34 of the avery tools catalog.

 http://www.averytools.com/catalog/2008%20catalog%20B.qxd.pdf

 then scrole down to page 34.  There is some good information about reamers and how to use them.  Since our skins are so thin, I never used any lubricant.  If I were reaming anything thicker then the diameter of the reamer, then I sure would use a lubricant.



 Off the top of my head, I don't remember what I used for the bellcrank but since I don't have a 1/4" reamer, it must have been a sharp 1/4 drill.



 --------

 Gary Blankenbiller

 RV10 - # 40674

 Instrument Panel, Fiberglass - SB

 (N2GB registered)

_________________
Kelly McMullen
A&P/IA, EAA Tech Counselor
KCHD

coop85(at)cableone.net
Guest

Posted: Sun Jun 29, 2008 7:29 pm Post subject: Aileron Bellcrank Bushing Questions

Les,  

   Lots of good answers on the reaming question, but I have a thought for the length of the bushing.  The exact number is not as much an issue as ensuring the bushing is slightly longer than the bellcrank.  Otherwise when you tighten the bolt you’ll add drag to the movement of the bellcrank.  

   

Marcus  

       

From: owner-rv10-list-server(at)matronics.com [mailto:owner-rv10-list-server(at)matronics.com] On Behalf Of Les Kearney

 Sent: Sunday, June 29, 2008 8:18 PM

 To: rv10-list(at)matronics.com

 Subject: Aileron Bellcrank Bushing Questions  

  

  

   

Hi  

   

I was working on my wings today and tripped over a couple of small issues.  

   

When filing the bellcrank bushings down to the required length, I made them slightly undersize (2.745” rather than 2.750”). Is this going to be an issue given that I am required to file the bellcrank tube to ensure at least 1/32 – 1/16” of the bushing is exposed?  

   

As well, I need to ream the bushings so that an AN4 bolt will fit inside. Reaming is new to me so I would like a little guidance as to how to ream these bushings. What do I use to ream them?    

   

Inquiring minds need to know  

   

Les Kearney  

#40643    	  Quote: 	
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        [quote][b]

kearney(at)shaw.ca
Guest

Posted: Sun Jun 29, 2008 7:31 pm Post subject: Aileron Bellcrank Bushing Questions

Thanks Ben and others.  

   

I now have a pretty good idea of what I should do – as much as I would like to buy a lathe, it does seem bit overkill for a couple of bushings. I’ll see if I can track down a sharp ¼” drill bit that will be long enough or perhaps a reamer.  

   

Cheers  

   

Les   

         

  

From: Ben Westfall [mailto:ben(at)sinkrate.com] 

 Sent: June-29-08 9:15 PM

 To: 'Les Kearney'

 Subject: RE: Aileron Bellcrank Bushing Questions  

  

   

Les,  

   

I cannot send to the list because the matronics server doesn’t like my mailserver right now.  I had a compromised mail account that sent some spam for a couple of days.  Should be cleared up tomorrow but until then I’ll have to try sending this directly to you.  

   

I used a really sharp, high quality .250” aircraft drill bit with lots of bolube (cause I had this in my stash otherwise I would have ordered a reamer).  I did the aileron bellcrank ones chucked up in a vise secured to the table on the drill press.  There are similar bushings in the control stick bases.  For these I used the same method except I used an electric hand drill… no drill press.  The bit follows the hole quite nicely.  The brass is so soft that it’s pretty easily done w/o a reamer or a lathe.  There is no slop in any of my bushings from what I can tell but I have not yet flown.  

   

I did screw up the first attempt because I forced the bit to much and it did not center.  They are cheap ($3 a pair I think) and Van’s is close so for me not an issue.  With a nice sharp bit its pretty easy to do them by hand.  

   

-Ben  

   

         

  

From: owner-rv10-list-server(at)matronics.com [mailto:owner-rv10-list-server(at)matronics.com] On Behalf Of Les Kearney

 Sent: Sunday, June 29, 2008 6:18 PM

 To: rv10-list(at)matronics.com

 Subject: Aileron Bellcrank Bushing Questions  

  

   

Hi  

   

I was working on my wings today and tripped over a couple of small issues.  

   

When filing the bellcrank bushings down to the required length, I made them slightly undersize (2.745” rather than 2.750”). Is this going to be an issue given that I am required to file the bellcrank tube to ensure at least 1/32 – 1/16” of the bushing is exposed?  

   

As well, I need to ream the bushings so that an AN4 bolt will fit inside. Reaming is new to me so I would like a little guidance as to how to ream these bushings. What do I use to ream them?    

   

Inquiring minds need to know  

   

Les Kearney  

#40643    	  Quote: 	
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Tim Olson

Joined: 25 Jan 2007
Posts: 2872

Posted: Sun Jun 29, 2008 7:46 pm Post subject: Aileron Bellcrank Bushing Questions

A reamer will work just fine in a drill.  It definitely does a

smoother hole than a drill bit.



Tim Olson - RV-10 N104CD - Flying

do not archive

Les Kearney wrote:

 	  Quote: 	
		   Thanks Ben and others.

 

  

 

 I now have a pretty good idea of what I should do – as much as I would 

 like to buy a lathe, it does seem bit overkill for a couple of bushings. 

 I’ll see if I can track down a sharp ¼” drill bit that will be long 

 enough or perhaps a reamer.

 

  

 

 Cheers

 

  

 

 Les

Tim Olson

Joined: 25 Jan 2007
Posts: 2872

Posted: Sun Jun 29, 2008 7:46 pm Post subject: Aileron Bellcrank Bushing Questions

A reamer will work just fine in a drill.  It definitely does a

smoother hole than a drill bit...and they're not expensive at all.



Tim Olson - RV-10 N104CD - Flying

do not archive

Les Kearney wrote:

 	  Quote: 	
		   Thanks Ben and others.

 

  

 

 I now have a pretty good idea of what I should do – as much as I would 

 like to buy a lathe, it does seem bit overkill for a couple of bushings. 

 I’ll see if I can track down a sharp ¼” drill bit that will be long 

 enough or perhaps a reamer.

 

  

 

 Cheers

 

  

 

 Les

johngoodman

Joined: 18 Sep 2006
Posts: 530
Location: GA

Posted: Mon Jun 30, 2008 3:17 am Post subject: Re: Aileron Bellcrank Bushing Questions

Les,

Check out this site:

http://www.panamericantool.com/



more reamers than you can imagine.

John

_________________
#40572 Phase One complete in 2011

orchidman

Joined: 10 Jul 2006
Posts: 277
Location: Oklahoma City - KRCE

Posted: Mon Jun 30, 2008 4:27 am Post subject: Re: Aileron Bellcrank Bushing Questions

 	  Kelly McMullen wrote: 	
		  Do you use the reamers in your air drill, or in a slower speed

cordless drill? Any thoughts as to whether it matters?

	


For the skins, I used both an air drill and a cordless drill.  As others have said it doesn't matter that much.  Thicker material needs the slower speeds to get a good finish inside and to preserve the bit.

_________________
Gary Blankenbiller
RV10 - # 40674
(N2GB Flying)

Albert Gardner

Joined: 10 Jan 2006
Posts: 455
Location: Yuma, AZ

Posted: Mon Jun 30, 2008 6:11 am Post subject: Aileron Bellcrank Bushing Questions

To square up the ends of bushings a lathe is not required. Chuck the bushing in your drill press and lower it onto a file clamped on the table. You will have to remove it several times to check the length but the ends will be square using this method.  

Albert Gardner  

N991RV  

Yuma, AZ  

Oshkosh ’08 or bust!  

   

   

       [quote][b]

_________________
RV-9A N872RV
RV-10 N991RV

kearney(at)shaw.ca
Guest

Posted: Mon Jun 30, 2008 7:58 am Post subject: Aileron Bellcrank Bushing Questions

Gary



I think I'll put the bellcranks on hold for a few days and order a reamer

from Avery. I can't seem to find one locally.



Given that I am now on my QB wings and have finished the fuse to the "boat

stage" are there any other sizes of reamer that I should order at the same

time.



Thanks



Les



--

Tim Olson

Joined: 25 Jan 2007
Posts: 2872

Posted: Mon Jun 30, 2008 8:25 am Post subject: Aileron Bellcrank Bushing Questions

The one for the gear leg holes if you haven't done that step

yet.  That's a definite one to get.



Tim Olson - RV-10 N104CD - Flying

do not archive

Les Kearney wrote:

[quote] 

 

 Gary

 

 I think I'll put the bellcranks on hold for a few days and order a reamer

 from Avery. I can't seem to find one locally.

 

 Given that I am now on my QB wings and have finished the fuse to the "boat

 stage" are there any other sizes of reamer that I should order at the same

 time.

 

 Thanks

 

 Les

 

 --

chuck(at)chuckdirect.com
Guest

Posted: Mon Jun 30, 2008 8:42 am Post subject: Aileron Bellcrank Bushing Questions

Or a piece of 150 grit glued to a short piece of 2x4"  wood.  

  

 Buy the appropriate size reamer. Clamp the bushing in a vice  with soft pine or piece of rubber between the vice and the bushing --- just  enough to keep it from spinning and hand ream it using a hand drill.  Make  sure you stay plumb with the work and it'll come out just fine.

 Chuck

 [quote]      

To square up the ends    of bushings a lathe is not required. Chuck the bushing in your drill press and    lower it onto a file clamped on the table.    You will have to remove it several times to check the length but the ends will    be square using this method.   

Albert    Gardner   

N991RV   

Yuma, AZ   

Oshkosh ’08 or    bust!   

    

 

 	  Quote: 	
		  



href="http://www.matronics.com/Navigator?RV10-List">http://www.matronics.com/Navigator?RV10-List

href="http://forums.matronics.com">http://forums.matronics.com

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     6/4/2008    4:40 PM

[b]

John Ackerman

Joined: 19 Jun 2006
Posts: 130
Location: Prescott, AZ

Posted: Tue Jul 01, 2008 5:50 pm Post subject: Aileron Bellcrank Bushing Questions

Here's something to watch for –

I reamed the bushings and still had unsat. operation. Turns out the  

brand new bolts were not straight. Used other bolts of same spec and  

all was OK.

I recommend going slowly and using lubricant. Don't run the reamer  

backward.

John Ackerman 40458

On Jun 30, 2008, at 8:55 AM, Les Kearney wrote:



 	  Quote: 	
		   



 Gary



 I think I'll put the bellcranks on hold for a few days and order a  

 reamer

 from Avery. I can't seem to find one locally.

 rums.matronics.com/viewtopic.php?p=190485#190485

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