Steve, you can’t be serious.
I'm thinking that a push pull linkage has the lateral forces cancelled out as one side pushes and the other pulls. The only thing left to counteract is the rotational torque of the servo.
One side pushes as the other side pulls, so you want to say each link splits the load, half is on one and half is on the other, fine. My single link is bigger in diameter, weighs the same as your two links do but will carry more load because it is stiffer (look at the buckling load of a column)
Now whether I have two links or one link “the only thing left to counteract is the rotational torque of the servo”.
I have drawn two diagrams depicting a dual link and a single link arrangement. It doesn’t matter what units you use but each will have the same load on the servo. It this case it amounts to 10 units of torque. On the left hand side of each diagram I put in some arrows with a value of 0 because there is no force at the center of the servo trying to push or pull the servo shaft longitudinally. The forces are torsion forces acting on the 4 rubber grommets of the servo which are more up and down rather than in the direction of the link.
……….and has the added benefit of not having to worry about getting perfect ball spacing and link angles to prevent binding.
You completely lost me here. Dual links require perfectly equal length links or you will not only bind you will break the link. It is like a toggle press where the forces are multiplied 100 times. The 5 units of force in each link go to 500 units of force between each other trying to tear each other apart. I think you may have broken your links because they were not the same length. And the link that popped of probably happened because they were stretched oversize over time and use.
Two things make a ball link come off:
1. they are too loose (oversize to the ball)
2. exceed the angle of the ball where the stem cams off the link (a link that buckles under column load is more apt to do this) Normally the more you push or pull the more the link wants to center on the ball and be retained. However when you start off with the link at an angle to the ball stem you have less allowable angle to work with before the caming does occur.
I've lost two helis in my illustrious career when the link rods have broken and had another link fail on a push pull setup that I only caught when doing some routine maintenance.
Sounds to me like you should be willing to rethink what you are doing.
What could be more fun?