Aileron System Repair And Modifications After 51+ air hours, the left inboard aileron hinge pin was worn out from vibration. I filed a slot in each end of the hinge at the pin location so that I could remove the worn pin. A new pin was slid into place. To retain the pin a short section of one end was bent 90 degrees, and a throttle wire stop was used on the other end. To remove play from the system that may encourage vibration, one side of the aileron horn clevis was cut away. The ball end of the push rod was bolted directly to the other side of the clevis. This removed play, about one eighth of an inch, that the ball could slide side ways in side the clevis on the pin. Safety washers were make out of .75 OD fender washers. I laid them on a socket and placed the ball of a ball & peen hammer on top of the center hole and then hit the other end of the hammer with another hammer. Dished the washers very nicely. Drilled the center hole of the washers out to .25 inches. Castle nuts were used and the bolts were drilled to accept cotter keys. Safety washers were placed on all ball end bolts.