Reaming Control Stick Base
 

I was working on assembling the Control Sticks today and wound up with an issue. In the photo below, there is a bushing that gets fitted into the control stick base. The bushing is supposed to fit an AN4 bolt, which it didn't so I reamed it with a 1/4" drill bit. Then the bushing was supposed to go into the control base, but it wouldnt fit. The bushing diameter was .375 as expected, but the powder coated base was just undersized. I deburred the edge on the base thinking that would help, but the bushing would go - even with a plastic mallet. I then deburred the outside edge on one side of the bushing, still no go.

So I decided to try to ream the Control Base. I use a 3/8" drill and placed the piece in my drill press. I slowed it to the slowest speed (620 rpm) and applied a good amount of liquid Beolube. I VERY slowly lowered the bit and it wasn't more than a second or two before it starting smoking and the heat was obviously building up as the powder coating started to shrivel up and discolor. So I stopped, let it cool and figured I was going too fast. So I waited a few minutes, more oil and tried again, same thing.

So I'm wondering, did anyone else have to ream their parts or was I just unlucky? If you did ream them, any pointers on how to do this without smoking the piece and ruining the base?

I'm off to Van's again tomorrow to replace the bushings (just picked up the missing ones today) and another set of the stick bases.

https://skydrive-df.live.com/embed?c...Ka6J6pA0uXtP3k

I sure don't recall that I did.

Hmmm, I hope I convince Van's it was a production mistake then as those stick bases are $63 each!

Charlie, I can't recall all the details now, but do remember that I spent a lot of time cleaning up the stick bases and getting everything to fit correctly. A lot of time.

Yeah, I removed quite a bit of powder coat to get the holes to align. It was no big deal and I just used a 1" Scotchbrite wheel to remove it. It took about 10 seconds.

Do be careful reaming those holes though. They can come out oblong pretty easily.

Bushings
 

I had the same issue. For the bushing, I tied using a drill bit but it ended up making the inner hole not very round. So bought new ones and used a reamer, came out perfect.

For the stick bases, did what phil did and used a small scotchbright wheel on a drill and cleaned the inside of the hole. Took no time and the bushings slid right in.

So no one had to ream the inside of the stick base itself? The 3/8" size hole in the base where the bushing slides into.

Give me the step you're working on in the plans and I'll see if it rings a bell.

I think we're all confused about what you're asking. Are you talking about the gold bushing and reaming the hole it slides into? Part numbers would help.

BTW - Your photo link isn't working.

Phil

There was a nasty burr and excessive powder coating on the ends of the bushing tubes on my sticks. I hit the holes with a countersink, then reamed the tube with a reamer,,,,not a drill. A light roll of the ends of the bushings on the deburring wheel and they slid right in with no problem.

If we're talking about that section of the stick, then that's exactly what I did there too.