Anybody else have problems with ArtHobby Aileron horns?

[rlt55]

These tiny little horns keep popping out at the field. I melted the the tips of the nylon shafts (on the lock plate) and still had one come apart last weekend.
The 'small' horns from the LHS look way too big.
(Maybe I should just cut them down and bolt them on).
When I was putting the tail on my Elster 1.5, I dumped the stock horns and made some out of CF. I'm not sure how to make horns for ailerons. Any pointers?
Thanks,
Rich<>

[Adam Neat]

Rich Ive made horns from lite ply and also circuit board material. Then just cut a slot and glue into place. Ive seen a couple places that sell Lite ply laser cut control horns for that purpose.
Adam

[Dave Seay]

I use fiberglass horns for flaps and ailerons. NSP sells a nice set. Cut a slot in the control surface, rough up the base of the FG horn where it will be epoxied inside the control surface and glue it in.

Make sure you weight down the control surface while its curing. Also, cut the slot a little wider that the horn. Its going to be emerged in a 'glob' of epoxy anyway and if you cut it too tight, the pressure from the tight fit might result in a slight warp in the control surface. My Addiction has a slightly warped aileron. It was about 1/8" over its length and thru a variety of means I've got it down in just under a 1/6". The plane flies well so I'll live with it. However, it won't happen again!

Dave