>| Bearing/casing/mount/hinge/pushrod loads depend only on the surface horn 
>length,
>| in inverse proportion.  Doubling the surface horn length will reduce these 
>| loads by half.
>But pushrod loads would be in porportion to the horn length, not
>inverse porportion.  Double the horn length, double the load.

No.  The horn length and pushrod force are related to the servo torque by

 horn_length * pushrod_force  =  servo torque

For a given servo torque, doubling the horn length will halve the pushrod force,
and vice versa.  

Example:  If you mount a 10" horn on the servo, how much force would
you have to apply at the tip of the horn to stall the servo?  Not much.
With a 1" horn, stalling the servo requires 10x more force.



>Not sure what you mean by hinge or mount loads.

The hinge, servo casing, bearings, mounting, etc. all see the pushrod force.
Reducing the pushrod force via longer horns will proportionately reduce 
the deformation of these items, and give an overall stiffer system.  Longer
horns will also decrease any slop due to oversize horn holes or loose 
clevis threads.


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