Today, I thought that I would find one of those "quick" jobs and came up with assembling the aileron bellcranks.  Well, once I found all the parts, I ran into the first problem.  The brass bushing that the AN4-32A bolt goes through had some dimensional challenges.  Van's cuts the brass bushing to the proper length (within 1/64"), however, the ID of the bushing is not large enough to run the AN4 bolt through.

I checked some other builders web sites, and at least one of them, made mention of this same issue.  The AN4 bolt has an OD of 0.250".  Definitely not the same dimension as the ID of the brass bushing.

No matter how much I wanted it to fit, it just wouldn't go.

This kind of crap, p_sses me off.  To do this correctly, and to what my wife calls my anal standards, this hole needs to be reamed out to the 1/4".  Why does Van's do that?  Their pre-punched stuff is so accurate, then the average guy has to cobble a solution to drill out a brass bushing to proper dimension.  Why not just supply a brass bushing of the proper ID dimensions? Heck, I have the tools to cut the bushing to the proper length...

However, I don't have the tooling (mill, reamers, etc) to do this correctly.  One of the builders I checked up on used a drill press and a 1/4" drill bit.  Now the trick here is to hold it such that it doesn't gouge the crap out of the outside of the bushing.

Drilling out the ID of the bushing didn't actually turn out to bad.  It didn't turn out as nice as if I had the proper reamer to take it to dimension.  However, the real  trick was to hold it during the drilling process.  I wrapped tape around the bushing to prevent the jaws of the vice grip from gouging the bushing.  This worked okay until the bushing got warm, then the tape adhesive got gooey and started slipping.

When I was done, I had some minor surface blemishes, so I chucked the bushing up in the drill press and sanded them out with a 400 grit sandpaper letting the drill press more or less do the work.

Even after my dissatisfaction with Van's on this, the aileron bellcrank worked great.  Very smooth and feels really good.  No slop in the bushing at all.

I torqued the AN4-32A and AN3-6A mounting bolts in accordance with the torque tables in the Standard Aircraft Handbook as follows:

AN4-32A:  60 in-Ibs

AN3-6A:  30 in-Ibs