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DONALD'S WEB SITE
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Date: 4-8-2012
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Number of Hours: 8.00
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Manual Reference: SNX-C01
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Brief Description: Rudder Pedals
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The rudder pedals are attached with phenolic blocks in a way very similar to the flap drive tube. However, the pedals are more complex because there are two holes per block, and a lot of alignment and geometry that has to work out for everything to rotate freely and correctly.
Having learned from my difficulty is making the flap drive blocks match the mounting holes, I did things differently. I aligned the top half of the block against the the mounting bracket, then used a 12" long 3/16" drill bit to start the bolt holes, just deep enough to get the full diameter hole started. I then moved to the drill press, locked the alignment of the block halves together, and drilled them together. This worked great and everything lined up well.
I spent a lot of time chamfering the blocks, test fitting the whole pedal assembly in the airframe, and taking them back out again. I could not get the pedals to rotate freely without sticking, so I started asking around for what I was missing.
Turns out that the trick is you are supposed to remove the powder coat from the area where the phenolic blocks are, since the bare metal has less friction that the 'sticky' powder coat. I did that using the factory technique of a blowtorch and a wire brush. I was worried that I had already removed too much inside the blocks, and with the poder coat gone there would be too much play in the tubes. It turned out when bolted in the pedals rotate freely and are tight in the blocks with no play...success!
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Rudder Block With Chamfer
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Pedals Attached to Blocks
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Powder Coat Removed
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