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Aileron Push-Pull Tubes and Rod End Fit?

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Ed T

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The aileron linkage from torque tube to the idler and from the idler to the bell crank are 3/4" x .035 wall round 4130 in the original plans and 3/4" x .049 wall in the Hale Wallace revision. The RE4H6 rod ends called out in the plans have a shank diameter of only 5/8". In other words, the ID of the tubes is between .055 and .027 to large to make a good fit with the rod ends. Has anybody come up with a good fix, perhaps a sleeve or use of shim stock to improve the fit? Just tightening the 3/16 bolts until the tubes flatten enough to grip the rod end does not seem like an acceptable solution. Have other builders addressed this poor fit-up? Any suggestions? Thanks.
 

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