Originally Posted by Mr. Wiz
Ya know, now that I think about it.... When I was putting the aileron control horns on I was having trouble getting the push rods to line up with the control horn holes. I ended up cutting about 3mm off the bottom of the control horns. How far back into the wing do you guys cut into the top of the wing to accommodate the pushrods? Also, I remember thinking the thing was pretty twitchy on the ailerons... even as I dialed in about 40% expo. Maybe I should go back and make new horns and cut further back into the wing top.... Maybe even get some pushrod shrouds and put them on there.
I relieve the pushrod slots about 3/4" back from the trailing edge into the top wing skins. It allows the pushrods to exit the wing high enough to line up with the holes on the aileron control horns. I would not advise altering the height of the horns. They are made to a specific size for correct geometry (assuming correct servo horn length (4.5mm) as well). Shortening the aileron horns by 3mm will increase surface movement a fair amount (more sensitive), plus put higher load forces on the servo gears and cases.