RWS327-Controls
Joy stick &
torque tube assembly 
I started the Controls 6 Oct 00
I seem to like the way a lot of things are done on the KitFox lite by SkyStar and decided to use a joy stick control system similar to the one it uses. Since I was designing as I went and didn't want to drill test holes in my fuselge, I build a mockup of the cockpit area. This allowed me to test differnt set ups and alignments of the various parts. Once I knew what/how I wanted it I could transfer the design to the real thing.
Flapperon controls and mixer
mixer model. (Please remember this is how I did it, it is not a recommendation of how you would do it. I am not a qualified engineer)
Here is my working model of my flapperon mixer. In the this picture the joystick(A) is neutral, the flap handle(B) is down. Note that both flaperons are neutral.
mixer model. In the this picture the joystick(A) is neutral, the flap handle(B) is up. Note that both flaperons are dropped. As the flap handle is raised the mixer bellcrank is moved rearward pushing both linkages back.
mixer model. In the this picture the joystick(A) is right, the flap handle(B) is down. Note differential in the ailerons, the right (up) aileron is deflected more than the left (down).
mixer model. A CAD image of the flapperon control, this is the view from the rear.
mixer model. View from the top.
mixer model. View from the left.
mixer bellcrank. Mixer bellcrank with rod ends in general location, a bellcrank bearing will be fitted to the hole in the upper center.
Bellcrank slider forward. Bellcrank slider assembly. The lower tubes will be anchored in bearing material. The mixer bellcrank rides on top of the upper plate. This is how it sits when the flap handle is down.
Bellcrank slider rearward. Bellcrank slider assembley. This is how it sits when the flap handle is up. The flap handle will attach to the close end of the left tube.
Flapperon interlock. From the mixer bellcrank I have push/pull rods theat connect to lever actuated torque tube which connect to the flapperon root. To have a solid connection and still have a fast set up I am using a socket connection. The Assembly you see in the picture to the left inserts into a 3/8" socket in the end of the torque tube. This asembly consists of a 3/8" square rod pressed and welded to a .125 plate (this photo taken before welding and radiusing). The overlap will be at least 1 1/2".
Flapperon interlock. To make the socket I epoxied and bolted a 3" length of 1/2" 6061 square tubing inside of the 5/8"round torque tube.
Flapperon Hinges
For the flapperon hinges see the wings page.
Rudder Controls
$$$. Rudder peddles, left view would use heal brakes the right view, toe brakes, once I decide I will finish them. The (not yet attached) peddle pads are sections of ladder rungs I found at the local metal recycler, (The ladder factory in just down the road).
Joy Stick assembley
$$$.
 
 In this picture you can see where the joy stick attaches to the torque tube.
$$$. The white square here (and the picture above) is some UHMW((Ultra High Molecular Weight Polyethylene is light weight, has a high tensile strength and is as simple to machine as wood. UHMW is self lubricating, shatter resistant, and abrasion resistant as well. White Color.) used as a bearing for the turque tube. John Statt provided this idea.
$$$. In this picture and the one below, the mock up is inverted, you see the bottom of the seat. You can see the triangular pieces welded to the torque tube that support the joy stick. The push-pull tube is inside the torque tube and attaches to the joy stick via a rod end (Aurora PN 44-4).
$$$. Bottom view of the rear torque tube bearing.
Elevator
 
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