Question PA28R-180 Rudder Bar Play

Hi Todd;
Sorry I didn't ask earlier but how was the the hole in the tubes repaired?? Weld then ream back to size??
Thanks,
Steve

Hi Todd,
Thanks for getting back to me. 
When you say a shop is repairing it; do you mean by welding it back to the original size?
I appreciate the feedback.
Steve

Thanks Steve for your research on this matter. We decided to remove the effected part and have it repaired.
Hopefully someone with more time and energy than I have (McFarlane) is chiming in and looks at securing a STC to use a tapered ream and tapered pin as in the Piper yokes use. That would be a easy fix without removing the rudder bar assembly and IMO a better solution for securing the system together. I did talk to a local FAA ASI about doing so under a field approval and being that its part of the flight control system that would be a longer road than what the customer wanted to wait for.
Anyways Steve thanks the support.

Hi Todd;
Piper tech support doesn't have a repair scheme for this problem. 
In the past Piper has had an engineer (that had to be paid for) to provide solutions for out of the ordinary problems, but apparently he is not taking new challenges now.
The Piper Tech suggested you contact a FAA Designated Engineering Representative (DER) and recommended Jon Moore at www.jbaerostructures.com.

His email is moore [DOT] jon [DOT] b [AT] gmail [DOT] com

I have no idea what he charges, or how long it will take him to provide a solution.

I am also going to contact him to see if I can learn more.

Please keep me in the loop on what you're doing.

Steve.
 

Hi Todd;
Based on your question, I did some research in Part 43 Appendix A and the following sentence under major repairs answered your question: "(xx) Parts of the control system such as control columns, pedals, shafts, brackets, or horns."

I'm going to Piper to see if I can get an answer to your question.

I'll get back to you as soon as I get an answer.

Steve

Hi Steve, thanks for replying.
What data did you reference stating that you can drill one size over going from a -4 bolt to a -5 bolt? I know we do that on sheet metal repairs all the time but I never have read that can be done on flight control tube's ect. Thanks in advance Steve, I appreciate it. That would be the easiest fix besides using a tapered pin like the yokes use IMO.

Todd