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Aileron Pushrod Spacer

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Skybolt540

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I wanted to ask if others have the following issue. My Skybolt wings were carefully made according to print. I recently installed new bellcranks from Steen.

The drawing below shamelessly pulled from Colleen's post, so ignore the captions for this thread.

My issue (for both the recent Steen and my previous bushing-style bellcranks from Hale Wallace) is that I need a substantial spacer (.345) in the location circled below which says "3/16" bolt with AN960-3 washer" between the bellcrank and the pushrod arm.

If I didn't add the spacer, I would have to notch out the spar along the pointer line that says "oblong hole in lower bracket arm." Actually, the ply IS notched out there a bit, right along the top of the red line shown, but not getting into the spar itself.

With 23° of "up" aileron and no spacer it's going to hit big time. Does everyone else have to use a spacer here, or is it just me? Should I notch out the ply more?


20100325_143913_aileron_bellcra.jpe
 
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