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Sonex 815 Build Logs
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Date:  7-1-2007
Number of Hours:  1.50
Manual Reference:  L01
Brief Description:  Brake cable installation

Cut the brake cable housings to length using the cutoff wheel in the dremel. Drilled hole in the lower LH motor mount for the brake cable housing end block. Drilled holes in the firewall for the brake cables. Made these holes large enough for a small grommet. There will be a little leak here. Bolted the cable end block to the motor mount. Ran the brake cable through the housings. Had to clean up the ends of the cable housing with an x-acto knife because the plastic liner gets a little gummed up at the ends (looks like the cable won't fit, but it does). Put the swivel on one end same as it was assembled when I got it. The swivel at the other end wouldn't put any crunch on the cable as it came, so I put the screw in the other end. Went back and reversed the first one. Pulled the brake handle - all this did was seat the cable housings in the end block - no pull on the brake levers at all. Loosened the LH swivel and pulled out about 1/2" of slack. Pulled the handle again - more slack, though I think the LH brake lever may have moved a little and stuck. So I tightened the swivel again. So far, my impression is the cable brakes work like crap. But other people have gotten them to work, so I'll keep trying. I like the idea of a turnbuckle for tension at the central pulley (kind of expensive for an aircraft turnbuckle), with thimbles and swaged-on sleeves at the brake levers. Also need to disassemble the brakes again and round off the cams some more. I don't see how these brakes work at all without rounding off the cams. And the LH drum isn't concentric to the axle, so it drags as it came. Need to disassemble the wheel/drum again and see if it can be made more concentric (whether the drum holes are oversize, or clock the drum on the bolts, or open up the holes so the drum can be centered better).
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Cable housing end block.

Cable housing end block.

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Swivel with reversed screw.

Swivel with reversed screw.

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