I was just looking through my photos from this summer at the NCFFA nationals and looking at one photo reminded me of something I though I should share with the guys in here.
I know for my self when I need the extra travel on an control surface I look to for the Dubro long servo arms in my servo-arm box. between that and the computer radios usually I can get the travel I'm looking for.
this summer I had a chance to look at some other builders and see different tricks. one guy had and interesting idea. he was making his own servo arms out of light ply. he would mount it to a round servo arm with two screws and presto you know have a servo arm as long as you want. Take a look at the attached photo to see what I'm talking about. look closely at the elevator servo on the boom.
this is as clear as I can get the photo

found a better photo. it looks like this guy actually used plastic.
different guys were using diffent methods.

I have taken two DuBro giant scale servo arms in the past, cut the ears off of one and fasten them onto the other arm in order to extend them. This has worked for me. I like this idea, if I can find the material.
Thanks!
Kevin

I bet it's G10...circuit board material. Tough stuff.

here is a photo of the whole plane.
someone must recognise the plane. maybe we can get the owner in here for some input.
on the wing it says Skunk Swatter.. has to ring a bell with someone

what about an old CD. do you think this plastic would hold?

I have a ton of G10..let me know if you want me to fix you up.

is it thin enough for a 256 clevis to grab on to?

It's 1/32" thick..I think you would want to laminate two pieces together to make a servo arm...I'll whip a couple up and report back.

CA glues it together just dandy..you could buy 1/16" material, but it's not free like this stuff

I'm interested in that G-10 you got chuck, let me know the price.

Well, for what it is worth, I have stopped using the Dubro arms and switched to sonictronics. The Dubro is too wide for full throw whereas the sonictronics is slimmer allowing more throw for the same size. Do not get me wrong, the Dubro is great, but the sonictronics is my new choice. Jeff Williams

Here is what I came up with...still need to screw the servo wheel to the G10 arm, but it is way stout!!

3" from hole to hole.

Weighs nothing...

Scole PM me your address and I'll hook you up.

Thanks ChuckAuger!

went to the computer shop today and asked the guy behind the counter for and old mother board.
took it home and cut a piece off. I then put it on the grinder wheel to remove all the contact points and electronics so it was smooth on both sides.
I then drew the shape I wanted on it and cut it with a cutting wheel on the dremmel. I sanded to the exact shape and attached to the round servo wheel. Finished by making the two holes for clevises.
chuck is right. this stuff is tough stuff.. and easy to work with.. and light weight.

.

Looking good!

Your new arm looks great but i hope you are thinking about the mechanical advantage you are losing from the extra length in the arm. The airplane you are seeing with the original arms on it is from New Mexico. That gentleman has been using them for years and i belive you are headed in the right direction with the Circuit board material. The other thing you should notice is the servos he is using have an out put torque i belive in the 130 in/oz range at 6 volts and he has offset his horns aft of the hinge center line to gain the mechanical advantage back from the extra long arms....just a note for you to think of.