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On the first flight after modifying the rig, the servo assembly failed. But the safety device worked. Replacing the servo took about an hour. To fasten the servo to the plywood plate, a bolt must be inserted through the geared rotation post at the top of the servo. This post is the component that causes the entire rig to rotate. I removed the plastic cover from the body of the servo and extracted the geared post. When drilling a hole through the post to accommodate the bolt, I used a different drilling method to avoid removing so much plastic as before. I used a drill-bit just big enough so that I had to thread the bolt into the plastic post. Then I drilled the larger bore for the head of the bolt by hand. With a gloved hand I held the drill-bit using it to ream out the plastic only a little.
Clearance is needed for the bolt head at the bottom of the post so that it does not touch the brass feedback post in the servo body. I used a fine hack-saw to cut down the brass post protruding from the body of the server. This operation allowed me to remove less plastic from the geared post, thus preserving its strength.
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