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Insert a VA-101 Threaded Rod End into both ends of the F-841 Pushrod. Drill #30 the eight rivet holes in both
ends of the pushrod while remaining within the edge distance dimension shown in “F-841 Pushrod Assembly”,
DWG 79. Cleco each hole as you drill.
Mark the position of both VA-101 Threaded Rod Ends to simplify reassembly (the holes will only align in one
position). Uncleco and remove the threaded rod ends from the F-841 Pushrod.
NOTE: Temporarily thread a
rod end bearing into both threaded rod ends to provide a handle for pulling it out of the tube.
Deburr the holes in the F-841 Pushrod and VA-101 Threaded Rod Ends that were drilled previously.
Clean the interior of the F-841 Pushrod by pulling a small cloth lightly wetted with solvent through the pushrod
with a string or piece of wire.
Reinsert and cleco the VA-101 Threaded Rod Ends into the F-841 Pushrod. Rivet the threaded rod ends to the
pushrod using the blind rivets specified (See “F-841 Pushrod Assembly”, DWG 79).
The VA-101 Threaded Rod Ends and the F-841 Pushrod are bare aluminum and must be primed inside and
out. Prime them after assembly because with the close fit of the threaded rod ends and the pushrod, it can be
very difficult to assemble after primer is applied to the parts. Priming the inside of the pushrod is easily accom-
plished by closing one end of the threaded rod end with tape. Pour a small quantity of primer in the open end
and then tape it shut also. Incline the pushrod so the primer runs slowly from one end to the other. Rotate the
pushrod slightly and then pour back to the opposite end. Repeat until the entire inside surface is coated. Un-
tape the ends and pour out the excess. Prime the exterior of the pushrod and threaded rod ends.
Thread on the rod end bearings and jamb nuts shown in “F-841 Pushrod Assembly”, DWG 79.
CAUTION: The
primer must be completely dry before installing the jam nuts and rod end bearings. Wet primer can mi-
grate into the rod end bearings and freeze the bearing.
The VA-101 Threaded Rod End on the aft (elevator) end of the F-841 Pushrod Assembly can interfere with the
WD-605-1 Elevator Horns if the rod end bearing adjustment is too short. The F-841 Pushrod Assembly has
been designed so that this rod end bearing is installed with maximum extension; just slightly more than 1/2
thread engagement. This prevents any interference between the threaded rod end and the elevator horns.
There is no interference concern with the forward threaded rod end and F-635 Bellcrank Assembly, therefore,
all length adjustments is accomplished with the forward rod end bearing. Adjust the forward rod end bearing to
achieve the overall bolt hole center-to-center distance shown in “F-841 Pushrod Assembly”, DWG 79.
WARN-
ING: After final adjustment, both rod end bearings must have more than 1/2 of their threads engaged in
the threaded rod ends.
This prevents the Pushrod Assembly from fully unscrewing from the rod end bearings
in the event that both jamb nuts become loose.
Make the F-840 Push Rod Assembly in the same manner as the F-841 Push Rod Assembly (See “F-840 Push-
rod Assembly”, DWG 79). To make a paper marking template for the six rivets at both ends F-840 Push Rod,
cut a paper strip to length, as done previously, but after folding it in half once, fold it into equal thirds.
Prime the interior and exterior of the F-841 Pushrod Assembly as was done previously with the F-840 Pushrod
Assembly.
Install the jamb nuts and rod end bearings on both ends of the F-840 Pushrod Assembly and adjust them to
achieve the bolt hole center-to-center distance shown in “F-840 Pushrod Assembly”, DWG 79”.
WARNING:
Both rod ends must have more than 1/2 of their threads engaged to prevent separation if both jam nuts
become loose.
Install the jam nuts and rod end bearings on both ends of the F-839-2 Pushrod Assembly. Adjust them for a
bolt hole center-to-center distance as shown in “F-839-2 Pushrod Assembly”, DWG 79).
Final-Drill 1/4 the hole at both ends of the WD-807 Control Column used for attaching the WD-411 Front Control
Stick and WD-412B Rear Control Stick Base.
Final-Drill #12 the rod end bearing holes in the WD-807 Control Column used to attach the control column to
the F-849 Fwd Control Mount and F-837-1 Aft Control Mount.
Final-Drill #12 the holes in the WD-807 Control Column used to attach the W-816 Aileron Pushrod Assemblies.
Remove the bushings that are supplied in the WD-411 Front Control Stick and WD-412B Rear Control Stick
Base.
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Use a file or sander to progressively remove material from the ends of both bronze bushings. Remove material
until they closely fit between the brackets to which they attach at both ends of the WD-807 Control Column
(See “Detail B” and “Detail C”, DWG 79).
NOTE: Finish the ends of the bushings to match the taper of the
brackets on the control column. This will prevent the bushings from developing a slight bend when the
bolts are tightened which can cause binding of the control sticks.
Use a file or sander to progressively remove material from the ends of the tubes which sleeve the bronze bush-
ings in the WD-411 Front Control Stick and WD-412B Rear Control Stick Base. Remove material until, when
bolted in place, the brackets on the WD-807 Control Column clamp on the bushings and just clear the tubes
(See “Detail B” and “Detail C”, DWG 79).. Do not remove so much material that there is excessive side play in
the control sticks.
Insert the WD-812 Rear Control Stick into the WD-412B Rear Control Stick Base. Mark the location of the re-
tention bolt and drill the #12 hole (See “Rear Control Stick Assembly”, DWG 79). Disassemble and deburr the
holes . Reinsert the rear control stick into the rear control stick socket and secure using the hardware specified.
Temporarily bolt the WD-411 Front Control Stick and the Rear Control Stick Assembly in place on the WD-807
Control Column.
Insert the F-839-2 Pushrod Assembly into the WD-807 Control Column and temporarily bolt it to the WD-411
Front Control Stick and WD-412B Rear Control Stick Base.
Adjust the length of the F-839-2 Pushrod Assembly so that the WD-411 Front Control Stick and WD-812 Rear
Control Stick are parallel with each other. Tighten the jam nuts of the Pushrod Assembly to lock the rod end
bearings in place.
The WD-411 Front Control Stick is supplied long and will have to be trimmed to final length. The maximum
length of the front control stick above the pivot bushing is shown in “Detail C”, DWG 79. The additional length
produced by a stick grip, and any switches that protrude from the top of it, must be taken into account when
cutting the front control stick to final size.
Remove the WD-411 Front Control Stick and Rear Control Stick Assembly from the WD-807 Control Column.
With the F-839-2 Pushrod Assembly still inside the WD-807 Control Column, position the control column in the
fuselage by inserting the aft end through the rectangular opening in the F-804 Center Section Bulkhead Assem-
bly from front to back. To get it started through the opening, lay the control column on its side, with the fwd end
angled to one side of the fwd cockpit area.
Install the rod end bearings and jamb nuts on the F-837-1 Aft Control Mount as shown in “Section F-F” and
“Detail B”, DWG 79. Temporarily mount the F-837-1 Aft Control Mount in place on the seat floors (See “Detail
B”, DWG 77). Install the rod end bearings and jamb nuts on the F-849 Fwd Control Mount as shown in See
“Section G-G” and “Detail C”, DWG 79.
Attach the WD-807 Control Column to the rod end bearings on the F-849 Fwd Control Mount and F-837-1 Aft
Control Mount using the hardware depicted in “Detail B” and “Detail C”, DWG 79.
Install the WD-411 Front Control Stick and the Rear Control Stick Assembly on the WD-807 Control Column.
Connect both ends of the F-839-2 Pushrod Assembly to the front control stick and Rear Control Stick Assembly
with the hardware specified.
Install the F-840 Pushrod Assembly by inserting it through the rectangular opening in the aft side of the F-804
Center Section Bulkhead Assembly, sliding it forward enough to drop the aft end below the F-830-1 Left Seat
Floor, then sliding the push rod aft through the opening in the F-807 Bulkhead Assembly.
Attach the F-635 Bellcrank Assembly to the aft end of the F-840 Pushrod Assembly (See “Detail A”, DWG 79).
Attach the F-635 Bellcrank Assembly to the F-818B-L-1 & -R-1 Baggage Rib Angles (See “Detail A”, DWG 79).
Attach the F-840 Pushrod Assembly to the WD-412B Rear Control Stick Base (See “Detail B”, DWG 79).
With the elevators still clamped in their neutral position, attach the forward end of the F-841 Pushrod Assembly
to the F-635 Bellcrank Assembly (See “Detail A”, DWG 79) and attach the aft end to the WD-605-1-L/R Elevator
Horns (See “Side View”, DWG 78).
Using the forward rod end bearing of the F-841 Pushrod Assembly, adjust the overall length of the F-841 Push-
rod Assembly so the Control Sticks are perpendicular to the upper longerons. After adjusting, tighten the jamb
nut and pushrod attach hardware. CAUTION: The rod end bearings of all pushrods must have at least 1/2 of
their threads engaged.
