We trimmed the control sticks for the grips, getting them to be tall enough that they clear the switches on the panel, but they were still hitting:
Trimmed control sticks in place
Stick grip hitting the flap switch
The angled bushings from Tosten helped, but didn't fully fix the problem - so I did what any reasonable person would do, I 3D scanned the stick and designed a new one:
3D scanned stick overlaid on a sketch of the extended stick
Options for the stick extension
Rendering of the extended stick
Scanned original stick overlaid with new stick
Attempting to get this fabricated, however, proved to be nearly impossible due to the 6" bend radius - the few places that actually gave me quote wanted something in the high 3 digits for it, so we resorted to the solution others have found, which is bending it a bit further.
I drilled the aft holes for the angled bushings:
Stick grip bushing installed and secured through screw hole
and primed the parts of the stick where the bending damaged the powder coating, as well as all of the top tip which remains visible even with the cover on:
Stick grips masked for priming
Primed stick grips
and finally, I installed the sticks and stick grips in place:
Sticks and stick grips installed in place, with the covers on
With this, the only thing left in section 39 is final-adjusting the pushrod lengths if needed, after all the surfaces are connected.
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