Brief Description: Brake line fabrication and installation
I had planned to fabricate and install both brake lines today but as usual I underestimated the time required. I used the copper test piece from yesterday to get a couple of the basic bends started for attachment to the bulkhead fitting. After a lot of trial and error I finally flared the upper end and snugged down the nut finger-tight. I then just used my hands to make the bends to run the line down the aft edge of the gear leg. I did the best I could matching the large strain-relief bend to the drawing in the plans. It may required some final adjustment when the wheel pant is installed.
Before flaring the lower end I cut some pieces of vinyl tubing and slipped it over the aluminum line for chafe protection. There is a 6-7" piece at the top to protect the line as it passes under the U bracket and around the gear bolt. There are three 3" pieces spaced evenly down the line where it is cable tied to the gear leg. Finally, there is another piece that covers the large looping bend so the line doesn't chafe against the inside of the pant. sliding the vinyl over the tubing was a challenge. It takes hot soapy water and perserverance.
After flaring the lower end and snugging everything down I turned my attention to the access plate. Using a unibit, snips, and some emery cloth to deburr edges I cut a slot for the brake line to pass thru with clearance. I think the line turned out pretty good. Will see if it can be repeated on the starboard side tomorrow.
