Captnem --
I am not an expert but I have used these rods a few time. One thing I found out is to put the "plug" on the wire before you make the 90 degree bend otherwise you may have to enlarge the hole in the "plug" to get it over the threaded end of the rod. Here is how I how I did mine.


1. Cut fiberglass rod to about 2-3 inches from servo horn measured while other end is attached to control surface (sounds like you have control end completed)
2. Measure 1 inch back from edge of fiberglass rod and drill hole (per instructions)
3. I then installed clevis on threaded end of metal rod
4. Slide "plug" on to wire
5. Insert clevis/wire rod/plug assembly into fiberglass shaft
6. Push or pull wire in or out until the clevis aligns with servo horn
7. Mark wire rod at front of "plug" with Sharpie pen
8. Remove clevis/wire rod/plug assembly from fiberglass rod
9. Align the front of "plug" (pointy end) with the mark you made on the wire and make a pen mark at the rear of the "plug" (flat end)
10. Slide plug forward (do not remove plug from rod) and make a 90 degree bend in the wire at the rear mark
11. Use Dremel to cut of excess wire from the bent portion leaving 1/4"
12. Insert wire into fiberglass shaft "hooking" 1/4" bend in the hole made in step 2
13. Use thick CA or epoxy to secure "plug" in fiberglass rod.
14 Done

It took longer to type this than to actually build the pushrod.

Anyway -- that is how I do it. Maybe others will have a better way.

Mark