Today I installed the flap position sensor. I tried a right angle drill bit to see if I could drill the torque tube without removing it. There’s just not enough room, so I reverted to unbolting it and moving it. I found by sliding it up in was able to get a clear enough line to drill the hole. I used a 12 inch drill bit and flexed it slightly to get square onto the torque tube.
With the hole drilled, I moved on to fabricating the connecting rod. This was easy enough.
Instead of using a molex connector, I followed the SteinAir how-to video and used d-sub pins and sockets to form the connections. Each wire’s connector is then covered with heat-shrink to insulate it.
With all that done, I installed the rod and then reinstalled the flap torque tube, which was the hardest part of the whole process. Then I mounted the sensor, and stopped for the day. I still need to tidy up the wiring, but will do that later this week.