control stick questions

[Flyguyeddy]

i have noticed an issue with the control stick page of the plans.  the torque tube and control stick are both 1" od aluminum, but the steel ends are called out as 1-1/8" diam with a .035 wall.  my math puts that at a bit of a sloppy fit.  are these supposed to be notched and made to fit tighter on the aluminum tubing?  

by slitting one side and welding back together i can see how that would work, but there is no mention of this.  

what have you all done?

[CHARLES DEBOER]

On my sketch #16 for the LE XL the torque tube is bolted to the stick with two halves of a split 5/8" square tube.  Both the torque tube and stick are 1" O.D. so that the split square tube halves don"t mate at an odd angle if they were different O.D. sizes.  They must be the same size.  The torque tube and the stick don't slip over top of each other.  

There is  a problem with the dimension of the 1" wood filler that slides inside the torque tube.  If you cut a notch into the 1" dowel for the cable that runs through the "T" tube it might fit into a 1" O.D. "T" tube.  If not, this could be solved by chucking a 1" dowel into a drill motor and sanding it down a little to fit inside the "T" tube.

[Flyguyeddy]

Im talking about the parts on the end of the torque tube, that get bolted thru at stations 2 and 3. 

[CHARLES DEBOER]

When you weld the 3/8" X 1/4" X 1" bushing to the 1.125" steel tube there will be weld penetration into the I.D. of the tube.  You may need to ream out the I.D. of both for a smooth fit.  The 1/4" bolt may have trouble sliding through the bushing.

[Tom XL-7]

If it feels sloppy add a 1/32" shim stock of any material. 1/32 may be too tight  Or wrap the tube end in a quality tape, or fill it with epoxy or....

[Poorman2]

I have thin shim material taking up the slack between tubes held in place by revits on mine.