ORIGINAL: seanreit
Gordon, can you describe in more detail what is holding the servo arm to the piece of hardwood? I get the 4/40 or whatever, I don't get "glued" to servo horn. Is that a nut on the other side of the screw? How tight if so? Just tight enough that it will turn? Assume too tight and it won't turn? So the glue is to keep the servo horn locked to the screw?
Yup - we want the servo arm to always rotate when you turn the ball-driver (otherwise you could be in a real mess if the screw keeps on turning and you suddenly have no way of getting the hatch off!!), so the cap-screw is simply glued to the arm to ensure that the arm will rotate on demand. If I recall correctly I actually glued a small nut on to the bottom of the servo arm too, I used Pic Plasti-stic to wick into the joint, then used Aeropoxy to make a fillet to hold everything tight.
The plywood plate is just there to hold the servo arm in the right position for you, so you want a tight clearance fit drilled through, then a washer & nylock washer on the other end that is tightened up enough to ensure that the assembly won't slop around, but loose enough to allow the screw to rotate when required.