More progress...
I decided to fabricate horns for the elevator halves. This will give it a custom look without seeing any screws securing them in place. Doing this however necessitates that you know exactly the position of the horn beforehand. Each horn was cut from .064" thick aluminum sheet stock. In addition, I am using custom pushrods which you will see. There are many methods to fabricate pushrods. Some builders use strips of wood, arrow shafts or lengths of either 2-56 or 4-40 steel rod just to name a few. While I wouldn't recommend using 2-56 rod on a plane of this size, 4-40 could be used. I decided against it because of the weight incurred from the two long lengths needed, as well as the bracing that would be needed to avoid flexing. Instead I’ll be using carbon fiber tubes which are strong, they won't need bracing, and they are LIGHT!
Template created for the elevator horn(s). Paper template will be traced on .064" sheet aluminum, I will need two separate horns.
I cut a slot for the horn to slip into. It is epoxied and pegged into place using toothpicks.
I further reinforced the horn by adding a short 1/4" x 3/8" balsa block to the side.
Bottom view of completed horn installation.
Top view. You can see the slots where they were slipped in place.
With the horns installed, it’s time to make-up the pushrods connecting the horn to its servo. I'm using carbon fiber tubing, purchased from Central Hobbies for this purpose. Titanium endpoints are inserted into each opening on the CF tube which are epoxied into place. I'm using JB weld for the epoxy. Simply squeeze out equal proportions of part A and B and mix thoroughly.
You should end-up with a uniform color like this when mixed. No need to rush as this product has plenty of work time.
I cleaned the inside of the CF tube with denatured alcohol before inserting epoxy .
This is the part that gets epoxied into the CF tube. One end is barbed and the other side is threaded (4-40).
After spreading epoxy inside the CF tube, spread a liberal amount over the barbs and insert it into the tube.
Notice the elastic band I have securing each end to the tube. When you insert the second end into place you are compressing air inside of the CF tube which may cause the ends to pop out while drying. The elastic band prevents this from happening.
