This is a perennial problem.
It has been next to impossible to get good quality clevises in China for a very long time, and they are only just becoming available. Right now on the latest shipments the clevises supplied, and the control horn hole diameter should be complimentary, but that does not make them OK for all the clevis types or IDS etc.
I drill the holes at 1.2mm which is slightly undersized in order to cover or be
purposely undersized for most of the clevis pin sizes. With so many types around we think this is the safest method and obviously far better than holes that are too large.
I'd love it to be standarized at 1.5MM across the board, but not so far. The pin sizes can vary between 1.2 to 1.8mm, so we opt for the smaller sizes so that they can be drilled out to the right size if needed.
Even for us is complicated: Here are the normal setups for models supplied to:
- Germany/Europe = 1.2mm diameter holes with the control horns fitted.
- USA (Under 3M) = 1.2mm diameter holes with control horns fitted.
- USA (Over 3M) Models supplied ready for IDS with control horns supplied but not fitted.
- UK = 1.2mm holes with the control horns fitted.
What I have done - yes I have the same problem - is to take a drill of the correct size for my clevises and then fit it into a peice of brass tube about 6" (150mm) long. It can be soldered or put in with Cyano glue - both work. Then I fit another larger tube over the end - in my case its a 6mm (1/4") carbon fibre tube to make a "boring tool" with the end large enough to provide 'Twiddling" purchase, but not so large as to give an obtuse angle to the horizontal.
This tool can then be used to bore out (twiddle) the holes to the correct diameter. YES, there will be a very slight angle between the horizontal plane and the drill angle, but if you take it carefully, step by step, and
attack the control horn from both sides, this is almost negligible.
Hope you have fun with your model!
Doc.