Joystick Assembly - Part 2

Fit the first push rod and front joystick - refer factory drawings. The connection for the pivot was made using a drilled AN4 bolt and castellated nut due to a remote chance of relative movement between the bolt shank and the mount. 

Pilot Joy Stick

Next insert the assembly through the hole provided in the No 3 bulkhead. Once in position install AN3 bolts with nylock nuts - do not tighten

Install the collar through the hole provided for the middle bearing in the main spar - slide onto the tube for its full length. A little WD40 helps the sleeve slide onto the tube.

Install the middle assembly - the joy stick was added latter. Insert it onto the front bay JUST enough to allow the front thrust ring to be installed, then slide the elevator rod into the opening. The pilot joy stick will have to be full aft during this operation.

Middle & Rear Assembly fitted
[Note: Pump is a trial fit to examine possible brackets and location] 

Inserting Elevator Rod - Note: Thrust Ring
Note: Grease on face of thrust washer

Rear Assembly

The bolt securing the elevator tube has to be disconnected to allow installation of the end assembly. Fit bearing assembly and slide to the welded lug. Fit sleeve and slide fully onto the end assembly tube - maneuver past middle assemble to engage bearing into rear spar.

Note: The assembly was painted, this prevented the bearing and sleeve sliding freely and had to be linished.

Assembly

Begin at the front by installing the stiffeners provided - tighten to allow installation of the stiffeners then back bolts off - repeat at the middle spar.

The bracket provided for this kit were originally intended to be installed at the rear spar but have been relocated the the main spar as shown. The builder chose to reshape to match the front assembly,

Front Stiffener

Rear Stiffener

It is critical the screws are install into the holes that the factory tapped.

All bolts must be loose for this task. Slide the middle assembly forward and then engage the coupling provided. Re-establish the correct position and then hand install each M5 screw.

 DO NOT FORCE

If the first one will not engage correctly rotate the assembly with the marks aligned and try another. If you have to use Allen key do so only when required and only after trying all the others - if none will engage by hand recheck the alignment.

Repeat at the rear assembly.  

At this point lightly nip all the bolts and check freedom of operation and if any binds exist locate and rectify.

Install the last elevator rod fitted with rod ends through the back of the rear assembly then refit the elevator tube.

Note: The screws supplied for the couplings are stainless steel and the instructions called for drilling the heads. This proved to be impractical and they were replaced with M5 Unbrako screws to allow the heads to be drilled as instructed in the plans.

All the working faces of the bearings are polished with 400 grit wet & dry paper by hand linishing. The bearings used are a glacier bearing and in theory require no lubrication but it was found that the application of grease at all working faces greatly reduced stick drag.

Co-Pilot Joystick
The two elevator push rods are connected at the same point as the co-pilot joystick. This was achieved by laying the assembly as far on its side as practical and using a small bar inserting the rear rod end into the clevis. A surplus AN3 bolt was used to capture both assembles then the correct AN4 bolt pushed thought to engage the assembly. The bolt was fitted with a light washer at the head, full washer and AN4 shear nut. 

The rod end of the co-pilot joystick should be adjusted to the same center distance as the pilot stock for assembly - repeat the technique outline above. The stick can be rotated in the housing for adjustment as required. Assembly joy stick to factory drawings - see photo front assembly

The elevator rods were painted red for high contrast at inspection

Re install stock stops in the tapped holes provided front and rear. Recheck assembly for freedom of movement.

Footnote: If any items are dropped into the tube during assembly they MUST be removed regardless of the effort required - failure to so may jam the assembly in operation due to the tight clearances.