Hey I am making custom control horns for REvolution and I heave a question. What type of material do you use for the wire that goes in the horn. I need an exact name for it. I know it is some kind of spring steel but not sure which one.

I've been using 7018 gas welding rod for quite a few years.  A2 is fine if plan on never have to adjust with a bend;  It will break.  7018 has a yield of 70,000 PSI, I've never had one fail, even through a crash.  FYI this is not my invention, I know of quite a few other people who fly and build much better than I and that is what they use.

I've been using 7018 gas welding rod for quite a few years.  A2 is fine if plan on never have to adjust with a bend;  It will break.  7018 has a yield of 70,000 PSI, I've never had one fail, even through a crash.  FYI this is not my invention, I know of quite a few other people who fly and build much better than I and that is what they use.

    I have had *no* issues with the A2 tool steel. I tried to bend a horn back an forth (as if I were tweaking it - a LOT) and my hands got tired long before it broke. Did the same test with music wire, and it broke after maybe 20-30 cycles (of +-30 degrees or more). I concluded from that that the tool steel, as used, was *much* tougher than music wire. My only concern is that it might be too easy to "tweak" because it is substantially softer.

    Brett

Guise here is where I am heading. There is no brazing in this horn. In my horns I bend 90 degrees and cut to length and the wire job is done.
A2 got it.

You selling this ?

Instead of having those long adjuster legs couldn’t you put the slot and screw on the same side as the pushrod?

Yes I understand. Can’t that slot and set screw be on the other side of the wire?
The adjustment set screw would be between the wire and the ball link on the control horn.
One half would have the control horn, with a threaded hole for the set screw. The other half would have a shorter ‘control horn’ with a slot for the set screw to tighten down on.
That would eliminate the long adjuster leg on the opposite side.

Hello Trian
                     I have made the Adjustable horn for the flaps in the past using that same idea not as beautiful as you have. There is a Thread on flap adjustment that made me improve mine to make it adjustable using a screw to be able to fine tune the flap after the first flight. Initially I used to use the horn I made to make absolutely sure that both flaps were parallel without giving any thought of fine tuning until I saw Paul Walker set up. I modified mine to be able to fine tune the plane`s flight but I haven`t been able to work on a new plane lately. I already have the wings built with the horn incorporated and can adjust from 0 degrees to plus or minus 5 degrees in small steps. here is the link to the thread so you can see the information and photos. Here is a pic.
                                                                                                                                                                                      Juan

https://stunthanger.com/smf/open-forum/flap-adjustment/