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Tool for attaching flight control surfaces without swearing

S

Scotsman

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Hey guys, I’m just at the point where I am attaching flight controls surfaces like the elevator and rudder to the HS and after ten minutes of cursing at my inability to insert the bolts into the rod end bearing I decided that I’d just try make a tool in onshape to do the job.

It seems to work well enough navigating the tight spaces on the tail feathers but have not tried the flaps/ailerons as I’m not there in the build yet. Just posting here in case someone wants the stl files.

Link to download from printables

IMG_3408.jpeg
 
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Clever design. I was reattaching surfaces at the paint shop last week fighting a little bit of this. We have it easy on the RV-12 but this would still be handy!

So...uhh....where's the file?
 
Scotsman said:
I’m just at the point where I am attaching flight controls surfaces like the elevator and rudder to the HS and after ten minutes of cursing at my inability to insert the bolts into the rod end bearing I decided that I’d just try make a tool in onshape to do the job.
Click to expand...

First time I've ever heard of a Scotsman wanting to do anything without swearing.

- mark
 
Washer wrenches are a cheap and invaluable addition to the tool kit - I'm sure you can build an RV without them, but I wouldn't want to.

And, +1 for hemostats, or just a good pair of needle-nose pliers, which I think is what I used here.
 
I use a long forceps to hold the bolt when installing the rear control surfaces. The forceps angles at about the right angle to do the job and it's inexpensive on Ebay.
 
I have a set of Temporary Assembly Pins for mounting the control surface. I also have tons of home made drift pins of all sizes.

I modified a pair of needle nose pliers for bolt insertion. They have a bend the shape of the bolt.

The printed doohickie is much better.
Are you sharing? How can I get the file?
 
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Over three decades (30-years) ago, the RVator newsletter published making this tool to help with installation.
IMG_4387.JPG

The old "Avery Tools" also sold these and it may have been something they invented.
IMG_4386.JPG

Yes, Van's aircraft made kit aircraft back then that did not have pre-punched holes in the sheet metal.
 
RV6_flyer said:
The old "Avery Tools" also sold these and it may have been something they invented.
View attachment 80257

Yes, Van's aircraft made kit aircraft back then that did not have pre-punched holes in the sheet metal.
Click to expand...
I used the old hex keys in the tool box to hold the elevator and rudder in place and then installing the nuts and bolts afterward. They act like the tools you show in the post.
 
The way i install the tail feathers is i use a piece of safety wire theu the boltl holes. Then i use hemostats to put the bolts in. The loop of safety wire holds it just enough so i dont drop it.
 
I have the Handee Clamp and a tool similar to Gary’s. Mine is not homemade. I think it’s made out of some spring steel or something. I have no clue where I bought it; probably Avery thoughIMG_3483.jpegIMG_3482.jpeg
 
wirejock said:
I have a set of Temporary Assembly Pins for mounting the control surface. I also have tons of home made drift pins of all sizes.

I modified a pair of needle nose pliers for bolt insertion. They have a bend the shape of the bolt.

The printed doohickie is much better.
Are you sharing? How can I get the file?
Click to expand...
Bought these from Cleveland and they were invaluable during installation of the control surfaces. Spruce sells them now.

Edit: sorry, I didn’t realize we were discussing the same thing. Good tool from at least 2 sources.

www.aircraftspruce.com

Temporary Assembly Pins | Aircraft Spruce ®

Temporary Assembly Pins Initial fitting of control surfaces require multiple installation and removals of the parts to fit, trim, and adjust everything. These temporary assembly pins make the task quicker and easier. Pins are 3/16 diameter
www.aircraftspruce.com www.aircraftspruce.com
 
PhatRV said:
I use a long forceps to hold the bolt when installing the rear control surfaces. The forceps angles at about the right angle to do the job and it's inexpensive on Ebay.
Click to expand...
+1, for maintenance. The seat latches on the RV-10 are relatively easy to remove at C.I. time, but a pain to reinstall. I use a large pair of forceps, maybe 10-ish inches long. I wrap a rubber band around them an inch and a half or so above the points, then insert the bolt near the points. With the proper number of turns, the rubber band provides enough pressure to hold the bolt for insertion, but then a gentle pull removes them leaving the bolt in place.
 
tom_AZ said:
+1, for maintenance. The seat latches on the RV-10 are relatively easy to remove at C.I. time, but a pain to reinstall. I use a large pair of forceps, maybe 10-ish inches long. I wrap a rubber band around them an inch and a half or so above the points, then insert the bolt near the points. With the proper number of turns, the rubber band provides enough pressure to hold the bolt for insertion, but then a gentle pull removes them leaving the bolt in place.
Click to expand...

Not to hijack the thread… but nutplating the rear seat slide stop bolts is a much easier way to remove the seats. Can have them out in under a minute no problem. Reversing is only marginally slower.

On topic- I have a very well worn set of the Cleveland temporary pins. I’ve had no issue using them, washer wrenches and needle nose pliers.
 
I bought this from the Lancair store, probably 15+ years ago. Similar to the OP’s printed part. Works GREAT. Have not been able to find it for sale. EVERYONE who has borrowed it wanted to get one.

Regards,
 

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Roy Thoma said:
I bought this from the Lancair store, probably 15+ years ago. Similar to the OP’s printed part. Works GREAT. Have not been able to find it for sale. EVERYONE who has borrowed it wanted to get one.

Regards,
Click to expand...
Dangit. I have one of those too! Oh bother!
 
I'm at the phase where I'm also _struggling_ with those bolts. I'd love a copy of the STL files if you could DM me.
 
Sorry guys despite managing to win with creating these in onshape I wasn't competent enough to upload the files to the original post as it was complaining about stl files not being an allowed file category. Sure that it is user error on my part but anyway I created a printables account and uploaded the two files there. Anyway here's the link to the two files, hope it works for you and shout if there was anything that needs changed as I bashed these up pretty quickly:

https://www.printables.com/model/1184110-aircraft-flight-surface-bolt-holder-for-vans-rvs/files
 
Scotsman said:
Sorry guys despite managing to win with creating these in onshape I wasn't competent enough to upload the files to the original post as it was complaining about stl files not being an allowed file category. Sure that it is user error on my part but anyway I created a printables account and uploaded the two files there. Anyway here's the link to the two files, hope it works for you and shout if there was anything that needs changed as I bashed these up pretty quickly:

https://www.printables.com/model/1184110-aircraft-flight-surface-bolt-holder-for-vans-rvs/files
Click to expand...
Thanks for the files! Worked for me...just printed a set.
 
Scotsman said:
Hey guys, I’m just at the point where I am attaching flight controls surfaces like the elevator and rudder to the HS and after ten minutes of cursing at my inability to insert the bolts into the rod end bearing I decided that I’d just try make a tool in onshape to do the job.

It seems to work well enough navigating the tight spaces on the tail feathers but have not tried the flaps/ailerons as I’m not there in the build yet. Just posting here in case someone wants the stl files.

Link to download from printables

View attachment 80236
Click to expand...
Scotsman,
Way to go. I've been searching for a now extinct metal version for over 2 years.
My son is into 3-D printing. I'll have him fix me up.
Best,
Daddyman58
 
Scotsman said:
what went wrong buddy?
Click to expand...
Not sure what is happening, it claims it is sliced, but nothing shows up. It is likely because I am a ludite. It's weird because every other time I can slice something I get a print. I don't think it is your files if others are having success.
 
RV6_flyer said:
Over three decades (30-years) ago, the RVator newsletter published making this tool to help with installation.
View attachment 80256

The old "Avery Tools" also sold these and it may have been something they invented.
View attachment 80257

Yes, Van's aircraft made kit aircraft back then that did not have pre-punched holes in the sheet metal.
Click to expand...
Gary,
What edition of the RVator was that bolt holding tool published in? How did the Todds Canopy you bought from me work out?

Charlie Kuss [rhymes with puss]
 
chaskuss said:
Gary,
What edition of the RVator was that bolt holding tool published in? How did the Todds Canopy you bought from me work out?

Charlie Kuss [rhymes with puss]
Click to expand...
I do not remember when it was published. I have all the RVators and have provided PDF copies to a Van's representative as they were going to put all of the past issues on the website before the financial problems started.

Have not touched the RV-8 project since I got the canopy from you.

My mother passed so as I get estate items and my personal life back in order, I hope to return to the project. If not, my Estate will have it to disposition.
 
MED said:
Bought these from Cleveland and they were invaluable during installation of the control surfaces. Spruce sells them now.

Edit: sorry, I didn’t realize we were discussing the same thing. Good tool from at least 2 sources.

www.aircraftspruce.com

Temporary Assembly Pins | Aircraft Spruce ®

Temporary Assembly Pins Initial fitting of control surfaces require multiple installation and removals of the parts to fit, trim, and adjust everything. These temporary assembly pins make the task quicker and easier. Pins are 3/16 diameter
www.aircraftspruce.com www.aircraftspruce.com
Click to expand...
I just took a nail & bent it with a 90 degree angle.
 
Scotsman, Great 3-D design!

Here are my tips for control surface fasteners.

I modified a set of needle-nosed pliers by chucking a 3/16" end mill in the drill press and squeezing onto it with the pliers (while it was turning a slowly). Result, a perfect tool to hold and insert hinge bolts.

I also slit a couple short pieces of 1/4" nylon tubing and place them as seen in the photo to protect the painted edges of the control surfaces. I prefer red so I don't forget them.

And I prefer to use an MS21042-3 all-metal locknut because they won't fall out of the 1/4" wrench as easily as the AN365 nuts do. A small piece of paper or masking tape in the box-end wrench can also help hold the nut.

That's my two-cents worth!

Control Surface Tools.png Needle Nose.png
 
Noice!

I will still swear, I inherited the sailor’s attitude from my Father.
It’s also good to see you, too, have blood on your tools (the wrench).
My “OSHA” signage displays “We have had “X” number of days without bleeding on this project”

- cappy
 
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