P-38 Elevator Control Horn FlightLine

thingiverse

An alternate elevator control horn for the FlightLine P-38L. Caution: This design requires filament material & printer capable of high layer strength. Test it before you install it and before you fly it. Design replicates most OEM geometry an adds 1) Increased flange surface area, 2) Compression plate with 2 screws to improve attachment of the control horn. Two STL files are attached. One with the 2 components of the control horn assembly. The other has 3 tools to aid in the modification of the elevator. I used 2.6x14mm and 2.6x16mm countersink wood screws. Adding FoamTac adhesive to secure this design is up to you. It might be possible to use 2mm screws, but I suspect 3mm is too large. Slice was done with 5 wall loops or 2 wall loops and 100% infill. Either way its solid and I could not tell the difference between the two. Similar finish. Similar strength. All of the functional holes are undersized by design. I used precision drill bits & a counter sink bit to achieve the final diameter & roundness. My final bit for the threads was 2.3mm and this was arrived at empirically. Your mileage may vary. Bambu X1C printer and Bambu PAHT-CF filament was used for the control horn and compression plate. PAHT-CF filament was in an active dryer @ 70F for 24hrs before printing. I used ASA on the tools, but any material with dimensional accuracy/stability should work on those. Note: Strength testing the plates on the control horn in ASA and PETG-CF resulted in relatively easy layer line fractures. Testing the print to failure before installation is a good practice for structural components. When strength is critical, I always print an extra sacrificial component to verify print quality.