With the tanks mounted, I’m ready to start installing the aileron actuation parts.
I started by preparing the main aileron push rods. I cut these to length then drilled the threaded rod ends. I designed a 3d printed drill guide to drill these holes (Onshape model available here).
![](https://airplane.allanglen.com/wp-content/uploads/2023/05/pxl_20230511_1310312285365558756593137031.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2023/05/pxl_20230512_1542347812330268053416530502.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2023/05/pxl_20230512_1542425554245417598280746024.jpg)
I then fabricated the shorter steel pushrods that connect to the ailerons. I made a small 3d printed drill guide for these holes also (Onshape model available here).
![](https://airplane.allanglen.com/wp-content/uploads/2023/05/pxl_20230512_0157179692296025514118663742.jpg)
The threaded rod ends are slightly larger than the inner diameter of the tube so I used sandpaper on a metal rod to widen the opening.
After match drilling the rod ends, I deburred the parts and primed the inside of the rods.
![](https://airplane.allanglen.com/wp-content/uploads/2023/05/pxl_20230522_0217384672792708904213610797.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2023/05/pxl_20230522_0217423053165822425909345129.jpg)
Other builders have mentioned that these are tricky to rivet due to the length of the rivets used and the hollow core in the threaded rod ends. I chose to use the rivet gun (instead of the squeezer). I found that a solid initial set gave me the best shop head as there was less chance for the middle to deform.
![](https://airplane.allanglen.com/wp-content/uploads/2023/05/pxl_20230522_032131062331903609833086479.jpg)
I deliberately set the shop heads well to provide clearance when assembled into the wings (others have mentioned that these can rub on the pushrod opening if they protrude too far).
![](https://airplane.allanglen.com/wp-content/uploads/2023/05/pxl_20230522_0321408088447668376263371465.jpg)
I then attached the jam nuts and rod end bearings.
![](https://airplane.allanglen.com/wp-content/uploads/2023/05/pxl_20230522_0333006565737067128216409706.jpg)
Next up was fabricating some spacers and bushings.
![](https://airplane.allanglen.com/wp-content/uploads/2023/05/pxl_20230512_1542081334597853031217625557.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2023/05/pxl_20230512_154259994501336230275735979.jpg)
Finally, I fabricated the aileron torque tube assemblies. These reside in the wing root area and transfer the motion from the stick push rods into the wing push rods.
I drilled the holes per plans and upsized them for AN3 bolts. I used a #13 drill bit followed by a 3/16″ reamer on all of these to avoid play in the bolts.
![](https://airplane.allanglen.com/wp-content/uploads/2023/05/pxl_20230512_154332793698097592802711241-edited.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2023/05/pxl_20230513_0140025751290949772384406218.jpg)
I’ll need to prime these before installing them but these are otherwise ready to be installed.