Making a “U” Bend

Tools | Main Menu
Zee Bend
Bending Landing Gear Wire | Bending Hard Brass Tubing
Motor Mount Drill Bushing Kit
Tap-N-Drill Guide | Wing Bolt Guide
Jim’s Film Trimmer | Easy Hinger

Step 1

“U” bends are a new way to make a pushrod end.  Everyone who tries a “U” bend never goes back to “Z”s.  We’ll show how to make a “U” in 2-56 rod that gives a nearly exact length pushrod. Use HWB332 for this.  For 1/16” wire use ZEE116.  First, lock the control surface in neutral.  The two photos will give you some ideas about how to do that.  Then attach the pushrod to the control surface horn.  

Step 2

Lay the pushrod on the servo arm, and with a fine felt marker, mark the hole location on the pushrod. 

Step 3

Remove the rod and make a second mark 1/4" farther away from the bend for either 2-56 or 1/16” wire.

Step 4

Place the rod in the bender with the mark closest to the pushrod end against one of the bender’s pins.  If this seems confusing, look to the photo in Step 5

Step 5

Make the U Bend.

Step 6

Use a diagonal cutter to remove the excess wire.  You’ll need to file the burrs off.  A Dremel tool with a cutoff wheel would be a better choice because it doesn’t leave any burrs.

Step 7

These photos show the completed pushrod installation.  The clevis normally requires no more that a turn or two and often nothing.

Tools | Main Menu
Zee Bend
Bending Landing Gear Wire | Bending Hard Brass Tubing
Motor Mount Drill Bushing Kit
Tap-N-Drill Guide | Wing Bolt Guide
Jim’s Film Trimmer | Easy Hinger