Originally Posted by ak79
Dave, what does your servo arm look like when you are at full flap? Is it laying totally flat so that the arm and linkage basically become collinear? I have been under the assumption that if that is the case then the servo is under less load at full flap since the load is basically being transferred from the gear to the output shaft itself.
In the picture above the servo arm is relatively flat but not touching the skin. I have about 80 degrees of travel on that panel (and all my x 2 panels)
You could also present better mechanical advantage by not burying the brass horn quite so deep into the surface and reduce the torque requirement especially at full travel. Maybe some of the more "mechancially inclined" would care to comment but I remember experimenting with different depths and found that just 1-1.5 mm of brass horm height really translated to lower servo buzz.