Recently I went back to the HS and elevators to drill the hinge bolt holes in the elevator control horns, using a drill bushing in the bearing. I drilled a #40 pilot and enlarged up to 1/4". However, after enlarging I found that there was not quite enough clearance to fit the hinge bolt & nut; the hole was drilled too close to the pipe of the elevator horn. After evaluating the problem, it appears to be due to slight angle in the elevator horns when they were welded. Every thing fit up well when they were fit when constructing the elevators.
I called Van's (they said this is a common occurance) and it was suggested that I grind down the bolt head a bit to allow for fit (the only interence on this side is due to the weld bead between the horn and pipe), and use a recessed nut on the bolt (allowing me to secure or turn on the hinge bolt). But, no joy; I cannot get the washer on and thread on the nut. There still is not enough clearance (maybe as much as 1/16"). An alternative suggestion from Van's is to fill the drilled hole (weld it full), grind it down flat again, thus repair the hole; back out the HS rod end bearings a bit and redrill.
This is where I am headed. I have friend who will fill it for me. However, I would like to get some advice from the group as to what welding material and method (Mig?) should be used to fill the 2, 1/4" holes.
Any knowlegable welders out there?
I called Van's (they said this is a common occurance) and it was suggested that I grind down the bolt head a bit to allow for fit (the only interence on this side is due to the weld bead between the horn and pipe), and use a recessed nut on the bolt (allowing me to secure or turn on the hinge bolt). But, no joy; I cannot get the washer on and thread on the nut. There still is not enough clearance (maybe as much as 1/16"). An alternative suggestion from Van's is to fill the drilled hole (weld it full), grind it down flat again, thus repair the hole; back out the HS rod end bearings a bit and redrill.
This is where I am headed. I have friend who will fill it for me. However, I would like to get some advice from the group as to what welding material and method (Mig?) should be used to fill the 2, 1/4" holes.
Any knowlegable welders out there?