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Date:  10-9-2016
Number of Hours:  2.50
Manual Reference:  
Brief Description:  Prop Control Bracket - Idea 8

Sam Jacobson came to visit yesterday. I was telling him about the various iterations of the prop control bracket. My then-latest idea of coming up through the left front baffle floor didn't look too promising as it is very, very busy under the engine and around the snorkel air ducts.

I had an ah ha moment when I held up a prior failed bracket. I decided that I could come in from the top. I spent 1/2 hour capturing key dimensions of the PCU5000 prop governor.

This morning, I dusted off my 3D CAD skills and sketched up a new bracket. (Figure 1)

I had planned to do a quick prototype with the CNC mill. At the last moment, I decided to print a proof-of-concept bracket frist. The fit was almost perfect. I checked dimensions on the printed part - the ABS was generally a good match to the 3D model, but the holes were under-sized in the printing process. I reamed them out about .010" and the fit was perfect.

I made a little angle bracket to mount the control cable. Good first it.

I came up with a couple minor improvements to improve the cable routing. The bracket has to clear the fuel feed (Right side of Image 2, below the bracket. Held by Adel Clamp). In the first version, I have about 3/4" clearance. This can be reduced to 1/4" to reduce bend in the control cable. I also can get the control cable mounting squared up a little.

Bottom line, the first CNC versoin, in .062" aluminum, should be the final. I was surprised how little flexing I got with the honey-combed 0.100" ABS part. Aluminum should be plenty stiff as-is. However, I can always add a stiffener if warrented.
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CAD Concept

CAD Concept

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Printed ABS Bracket - Perfect Fit

Printed ABS Bracket - Perfect Fit

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Added Control Cable - Good Fit

Added Control Cable - Good Fit

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