Notice how everything is interlocking. Makes it impossible to build one wrong.
Dual box for elevator servos
Completed box
Single boxes for aileron servos
You can see how the system works. The arm is epoxied into the control surface and the servo slides into the box, thus eliminating linkages, hardpoints, slop, weight, etc.
Control horns being made.
I glue the arm to the wood since I won't ever be changing the arm. The teeth will never get sloppy since the load is always at a perfect right angle on the control horn.
An aileron box hole ready to be cut into the wing
A pic of where both boxes will go
The hinge line cut out for the box
The foam cut out for the box
The box slid into place to make sure it fit in my hole
There is a hole laser cut into the center of the box that the hinge wire can slide through to let you know that the box is centered on the hinge line.
That is about the only important thing to remember when installing this system is to just keep everything centered in relation to the hinge line.
The dual box in the elevator
Making some more control horns. These are for the ailerons. Using 5955s on them and 8611s on the elevators and rudder.
For the control arm, just run the hinge wire throught the center of the servo arm hole and you know that is centered. Just make sure it stays there until the glue dries. I use a lot of micro balloons to help keep it from sliding around all over the place.
A finished look from the top of the elevator
You just attach the servos one at a time with the arm screw
The other one. Obviously do the one in the back first.
You can also get a head start on the matchbox at this point by looking down the side of the servos and making them line up before putting them in the wing/stab.
Then you just have to fine tune the matchbox a little after installation.
Then connect the wires like normal and slide the servos into the wing or stab.
What it looks like with the servos installed.
The little holes are a place you can install a 4-40 bolt and locknut to keep the box from spreading. I didn't use this on my extra and never had a problem, but it still isn't a bad idea to use and since these have the hole already laser cut for me I'm probably going to use the 4-40 bolt on this one.