On Sep 26, 12:34 am, cavelamb himself wrote:
Ed Sullivan wrote:
On Tue, 25 Sep 2007 21:58:46 -0700, "Steve S."
wrote:

Folks:

First let me say that I know well that everything is supposed to be in
double shear. Lord knows I have busted my butt to make sure
everything is in double shear.

But.

I have a portion of my aileron circuit that has a fork fitting to
provide the requisite double shear. However the bolt hole in the
crank is seeing some misalignment and is starting to wallow the hole.
I really, really should replace the fork fitting with a rod end (i.e.
it never should have been a fork fitting to begin with, it was a spur-
of-the-moment fix that was really just a band-aid). But the crank
being driven by the fork is going to be impossible to replace with a
two-armed crank that can nest a rod end.

Now, with all of that said, here's my question: How bad is it really
to have the rod end in single shear if I do the washer trick? It's an
aileron rod, I do not think it sees much load at all--certainly far,
far short of it's rated load. I have seen several planes out there
with rod ends in single shear, so it can't be complete suicide . . .
right? No?

Thank you for your thoughts.

I have a number of them that have been in service for over 20 years,
all with the large washer. Works for me.

Ed Sullivan, Jungster II

Long as teh arm and bolt are stiff enough not to deform - who cares...

The single arm may not have the resistance to twisting that
the two arms do together. You'd want to compare single-arm setups with
what you have. An arm that allows twisting will eventually fail or
might allow enough aileron play to start flutter. Both are bad news.

Dan