We took the center control quadrant apart today and found the bolt hole in the aileron control bell crank to be slightly elongated.  It appears to be about 1/10000 out of round. This resulted in approximately 1/8 inch of slack at the end of the rudder bell crank.

 

As for a cause, the only idea we have is that the aircraft at some point might have been out of rig and was flown with a constant control pressure in one direction.  The constant pressure combined with the natural vibrations of the airframe may have caused the bolt hole to wear on one side.

 

Our plan at this point is to ream the hole back into round and then use a 1/10000 oversize bolt.

 

The attached photos (19 & 20) show the slack and (21) the elongated hole.

 

Thanks to all who have offered ideas and advice and if anyone has a better idea we are certainly open to suggestions.

 

Tommy

N93929

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