Concealed Aileron Control Linkage

thingiverse

New Version 2 Design After conducting extensive testing, I discovered that using skewers even for short sections is not ideal for this linkage. Each piece of wood has a different amount of torque it can handle, causing the skewers to torsion under load at varying rates, resulting in an unstable aircraft. Version 2 now employs 1-1/2" long brad nails as a substitute for the skewers, providing a more reliable connection. Additionally, I experimented with various adhesives and found that Gorilla brand super glue works best for securing the nails into place. Although the holes should be tight to begin with, this adhesive ensures a strong bond. In contrast, hot glue proved rubbery and failed to hold well, while several other brands of super glue did not bond as strongly. When installing the raised side of the linkage, it is essential that it aligns perfectly with the pivot point of the ailerons' hinging motion. This design was initially created to work seamlessly with simple beveled foamboard hinges but also features matching hinges. These custom hinges offer easier alignment and are not required for this linkage, though they provide an added level of precision. Visit Thingiverse at https://www.thingiverse.com/thing:2535238 to access the design files. To assemble the linkage, use a 1-1/2" long brad nail or similar material to connect the components. Ensure the arms are snug while the hub section spins freely. Use CA glue (super glue) when attaching the arms as additional reinforcement for added stability. Note: As I am aware of the limitations of my old 3D printer, I design with these quirks in mind. Specifically, holes often print smaller than their intended size due to minor inaccuracies. To avoid any issues, test print each part and verify that attached hardware such as wire or skewers fit properly before engaging in bulk printing. View a detailed tutorial on the assembly process at https://youtu.be/FSGpKo0apI0.