I need help. I just flew a fancy foam extra and the aileron thros are way to small, and there at machanical and electrical max. I want to get them at about 45*. How do I do this?

The distance from the center of the servo to the hole the pushrod connects to in the servo arm, should measure the same as the control surface to the hole the pushrod conects to in the control horn. This will give you a one to one travel. (i.e. 60 degrees of servo travel should translate to 60 degrees of control surface travel.

If nothing else stick the pushrod farther out on the servo arm, and closer to the control surface on the other end!

Well, if you have a computer radio, you can adjust the EPA (end point adjustment) so that the servos move to a point you feel is good enough for you. Otherwise, change the holes like he said.

I have done all of that and I have aprox. 35* movement but I want aprox. 50*. My expo's are at full 120% and the rods are at the last hole on the arms and the first hole on the horns? Got any ideas?

Try to find some longer servo arms, might help, a little.

Matt:
What is the distance from the centre of the servo arm to the outer hole, and what is the distance from the surface to the hole in the horn?

I think it is the servo travel itself. Make sure you are getting at least 45 degrees of travel. If you are not, you have probably set up something wrong on the transmitter.