Great Planes Extra 300S 1.60 ARF - GPMA1365 - Manual (Page 8)

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5. The aileron has a plywood plate for mounting the
control horn. Using a T-pin, lightly puncture the covering to
be sure you are over the plywood plate. Position a large
nylon control horn on the aileron, positioning it as shown
in the sketch and aligning it with the servo. Mark the location
for the screw holes. Drill through the marks you made with
a 3/32" [2.4mm] drill bit. (Be sure you are drilling into the
plywood plate mounted in the bottom of the aileron. Drill
through the plate only. Do not drill all the way through the
aileron!) Using a #4 x 5/8" 16mm] sheet metal screw, install
and then remove a screw into each of the holes. Harden the
holes with thin CA. Install the control horn with four #4 x 5/8"
[16mm] sheet metal screws.
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6. Locate a .095" x 12" [.095" x 305mm] pushrod wire
threaded on one end. Screw a 4-40 nut, a silicone clevis
keeper and a threaded metal clevis onto the threaded end
of the wire 20 turns. Tighten the nut against the clevis and
then install the clevis on the aileron control horn.
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7. Be sure the aileron servo is centered. Enlarge the
outer most hole in the servo arm with a Hobbico Servo Horn
Drill (or a #48 or 5/64" [2mm] drill bit). Install a 4-40 metal
solder clevis onto the outer most hole in the servo arm.
Center the servo arm and center the aileron. Using the
solder clevis as a guide, mark where to cut the pushrod
wire. Remove the pushrod and clevis from the control horn
and the solder clevis from the servo arm. Solder the clevis
to the pushrod using the “Expert Tip” that follows.
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8. Install a silicone clevis retainer over the solder clevis.
Install the pushrod and clevises to the servo arm and the
control horn. Adjust the linkage until the aileron and the servo
arm are both centered then tighten the nut against the clevis.
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9. Repeat steps 1-8 for the left wing panel
HOW TO SOLDER THE CLEVIS
TO THE PUSHROD
1. Where the pushrod will make contact with the solder
clevis, roughen the wire with 220-grit sandpaper.
2. Use denatured alcohol to remove any oil residue from
the pushrod wire.
Note: Soldering should be done with silver solder not an
electrical solder. Great Planes
® has a convenient Silver
solder kit (GPMR8070) that includes flux and solder.
3. Apply a couple of drop of flux to the wire. Slide the
solder clevis onto the wire. Using a small torch or
soldering iron heat the wire, allowing the heated wire
to heat the solder clevis. Apply a small amount of
solder to the joint. When the wire and the clevis are hot
enough the solder will flow into the joint. Avoid using
too much solder causing solder to flow out of the joint
and clump. Use just enough solder to make a good
joint. Allow the wire and clevis to cool.
4. Put a couple of drops of oil onto a rag and wipe the
joint. This will prevent rust from forming on the joint.
Correct Incorrect
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