Seriously, I did discover the need for that area washer when I was reviewing the Trutrak drawings.   Thanks to the responses who caught that problem.  I also found 3 more places with similar exposure.   To test what might happen without the washer, I dropped that arm and moved the stick.  It locked in a hard left turn when the rod dropped down and got stuck near the actuator.  There would be no cure for that situation in flight.   Therefore, I have decided to spend the $0.06 each on the larger washers.

Grayhawk, there was no hose interference but the other end of that rod had a slight rub on the aileron control rod so a spacer was added to fix that.   For actuator runaway, the ailerons must have a hard stop built in because the actuator can't be moved more than about 45 degrees off top center which is full stick deflection.   

My original problem was fixed with the nylon shear screws which you can see below.  Two bags at $0.59 each from Lowes and I believe they are Trutrak approved.

Paul

Spruce Creek