4/29/2007
Today was ALL about brakes! We were supposed to have another tailwheel lesson today, but the winds were blowing 20 gusting to 30, so no wheel landings today. Instead, I got a FULL day in the garage working on the brakes, and I got 'em done! LOTS of pics from today!
I started where I left off last night with drilling a couple more holes for the bracketry that attaches to the pedal.
After that was done, I prepped the pedal parts for primer and paint. I decided to go only with pilot side brakes. The right side brakes would never get used, and would just be extra dead weight, plus no crossover brake line system. Simpler. From this point on, I assembled the brakes in reverse order. I saw no point in putting the pedals in before the rudder bars were fit. They would be in the way, and there is no reason for them to be there at this point. I put them in in the end.
While the primer was drying, I started working on the plastic rudder bar blocks. These get drilled, and the middle one is split down the middle.
I also made the rudder cable attach links.
Those were primed as well, and the first hole was drilled. The second will depend on pedal location.
The rudder brace was next, and I made the necessary trims, rivet holes, and lightening holes.
Then I clamped the blocks to the longerons to drill the position holes. I made a mistake that will render one of the positions useless because I missed the required two hole distance between holes on the left side. Not a big deal, I just won't be able to use them. It's not like they will be moved frequently anyway, and the seat back adjusts as well.
I drilled the two holes for this position, then marked the other positions and drilled those.
The bars were "lowered" in place (it is upside-down ya know...), and I bolted the blocks to the longerons.
The rudder brace was then clamped in place, and it was drilled to the firewall stiffener and drilled/bolted to the middle block.
At this point, I went back to the rudder pedals. They were now dry in their freakin' awesome red paint! I riveted the parts to the pedals.
You notice in the close up below that I rounded the trims, instead of a straight angle. Looks much better, even though no one will really see them.
After fighting with the stupid washer fitting in between the bars and the pedals, I used a rule clamped to each pedal to make sure they are lined up for fitting and drilling the master cylinders.
Then the master cylinders were bolted up, and we have brake pedals!!!
Loooooooooooong day today, but totally worth it!
8.5 hours