Boy you are not kidding! The first time I flew my Mark IV I flew out to a friends local grass strip. The wind had picked up and a rotor off of some trees about put a wing into the ground. It scared the crap out of me. That's when I knew something was not right. The aileron roll control was very heavy. It is amazing what a small adjustment did for that plane. It went from very heavy to light and nimble. I kept getting air in the left line going up to the reservoir. I would bleed it out but after a few pumps it was back. The shaft in that M/C was scratched up like someone had grabbed it with a vice. I tried to clean it up but I think it had already ruined the o-rings in the top cap. I installed a new shaft, top cap and o-rings last night so I should have it all back together and working this evening. Yeah those have to be the best looking gear I've seen on a Magnum. As soon as my Dad decides to sell this Magnum to me I'll start looking for gear options. Was he able to build them from a jig or did he have to have the airplane on site? Do you remember what he charged you to make them up? Thank you for the information Barry. That sure a good looking airplane. I hope to get my hands on this one of my Dads.
I had the same issue with my Mark IV flaperons. Mine were 3 degrees off. Setting them right made all the difference in he world. I should have my Magnum ready this weekend. I had to rebuild the left master cylinder because it was pulling air into the system. I love your landing gear. Did you built it?
Several of us Zenith Builders did the same thing when lengthening the wings. The ones that flew them both ways said they noticed little to no difference. After talking to a few of the guys I opted to not lengthen my ailerons. I have not flown mine yet but do not anticipate a problem based on others reports.
Dean Wilson repaired the aileron hangers on my Dads A model using a fiber overlay method. Its been a few years ago but I believe he used carbon fiber You have probably ran onto my last repair using Aluminum and scotchweld. A re-coat of spar varnish will be required every couple of years or when a person see it's needed during a preflight. A light sanding and coating takes no time at all and gives me a reason to give them all a good look over.
I was down in Lewiston visiting Dean Wilson many years ago. We walked outside and there an Avid setting on a trailer backwards. He looked at me and said “I never figured out why people would haul these things backwards. I told him that I figured it must be easier to convert a small trailer for it. He agreed and said he didn’t like it. The reason I remember it so well is I had thought the same thing myself. I have a backwards hauling Avid trailer and I’ve hauled them nose first. I prefer nose first. The things I like about hauling nose first is the wings move/flutter less at higher highway speeds, the plane takes gusts from big vehicles better and if for some reason a wing was to come loose it’s not going to open. As far as the open end of the wings, I cut up some of those silver car window shades and tape them over the ends of the wings with 2” wide painters tape. Support the tail good and it’s a pretty good ride. Id still rather try making love to a bobcat in a phone booth as haul another airplane anywhere.
While you are at it you might as well change the lower master cylinder attachment point from the rudder bar to the floor / firewall. This seem to correct the geometry of the master cylinders and gives you better braking over the stock setup. I'm sure someone on here can provide you with instructions on how they did it. I will eventually be doing it to mine.