While changing out my flap rods this weekend (see
http://lancaironline.net/lists/lml/Message/22841.html) I got a couple of
rude surprises.  The first one was the left rod is bent (about 1/8" bow
in the middle!).  Graphic proof of why the fatter rods are needed!
Next, the left rod is 1.18" longer than the right one (8.92" vs. 7.74",
measured center of bearing to center of bearing).  This is not just a
matter of adjustment.  The actual rods are different lengths (7.10" vs.
5.65").  My first thought was I would just adjust the new ones to match.
Wrong!  The new rods are 6.5" long.  For the left rod, using the minimum
allowable amount of thread engagement on the rod ends, I can only adjust
the new rod to 8.55", leaving me 0.37" short of a one-for-one
replacement.  Doesn't sound like much, but it equates to a 1.3"
difference in the position of the trailing edge of the flap (yes, I
actually installed it and checked)!  So my next thought was, I can make
up the difference by adjusting the push-pull tubes between the flap
bellcrank and the flap actuator bellcrank (or whatever that's called)
and/or by adjusting the limit switch on the actuator.  However, it
appears (I haven't pulled it out to check, yet) that there is very
little if any lengthening adjustment left on the rod ends (already over
an inch of thread exposed on both ends).  Also, I couldn't tell by
looking if there is enough adjustment on the limit switch to compensate.
To further complicate things, on the right rod I cannot adjust the new
rod short enough to match the old rod, let alone match the 0.37"
difference on the left side.  I can cut about 1/4" off of each end of
the new rod and that would allow me to match the bearing to bearing
length of the old rod but will not allow me to make up the additional
0.37" to match the left side. (I hope this is making sense.)  However,
it appears I can adjust the right push-pull tube to make up the 0.37"
(yes, I know the lever arms on the bellcrank are different lengths and
it will take more than 0.37" of adjustment on the push-pull tube to get
0.37" at the flap rod).

So my question is, what's the easiest way to deal with this?  Would it
be simpler to just get new rods fabricated to match the old ones?
Anybody know what material those rods are?  They appear to be some grade
of steel, anodized after threading.

Lee Metcalfe
N320WH - LNC2 - IO320+ - 517 hrs. - Kansas City