Make a bracket out of 1/4” X 1 1/4” X 1 1/4” X 1/8” wall C channel,

2 1/2” long. This piece holds the down tube that connect the stick.
Drill this on your table, with the torque tube bellcrank assembled. Make
sure
that you drill the hole 90 degrees to the bellcrank, and in the proper
position.
Now make the down tube, which is 4 1/2” long. There is a sleeve in this
one
also.
Take the C channel down tube connector off of the torque tube.
Make the torqe tube end play bearings out of PVC pipe, 1” I.D. These
are 1” wide. Slide the torque tube through both angles, inserting the PVC
bearings as you go. Postion the torque tube so that there is 1/2” clearance
between it and the cross tube. Making sure that the PVC bearing is on the
forward side of the forward angle, drill a 3/16” hole through the pvc and
one
side of the torque tube. Now do the same for the rear PVC bearing, making
sure that it rest behind the rear face of the rear most angle. You want a tight
fit, with no play forward to back, but not to where it will bind. Bolt the
down
tube assembly into place.
The rod end connector connects the torque tube to the control stick.
Cut a piece of threaded rod, fine thread, 1/4” diameter, 9” long. Assemble
the rod ends, and stop nuts. Be sure to slide the 1/2” tubing over the
threaded
rod before securing the rod ends. Adjust the rod ends on the threaded rod
until the torque tube down tube is vertical, and the control stick is vertical.
Then tighten the stop nuts against the rod ends.
The aileron bellcrank assembly is fabricated next. Make a fitting out
of 2” X 2” X 1/4” X 6” long 6061-T6 angle. Clamp the angle in place on
the
fuselage and drill the two holes shown on the plans. Drill the holes for the
pulley asemblies. Now add the pulley assemblies and bolt the unit to the
fuselage.
The rear aileron bellcrank assembly is started by cutting a scrap piece
of 2” X 2” square tubing to the shape shown on the plans. Drill and bolt
this
is place on the fuselage.
The aileron bellcrank is made from .090 6061-T6 plate. Make a hole
in the center of this piece to accept the machined bellcrank. Pop rivet this in
place. Now bolt the bellcrank to the square tube.
The aileron control rods can be fabricated now. Bolt these in place on
the bellcrank.