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Jims RV-8
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Date:  11-12-2014
Number of Hours:  1.80
Manual Reference:  8-62
Brief Description:  Rudder pedals - #3

More rudder pedal work. More final drilling of holes and deburring and then the pedals were bolted on and were tested for smooth movement. I went to mount the bottoms of the brake master cylinders to the rudder slide lugs. The right master cylinder went on no sweat, but the left one wouldn't line up properly to allow the attachment bolt to slide thru. Looking at the lug and the master cylinder - it seems that the master cylinder shaft was made a little smaller than the right one and is bottoming out on the lug. I could either hollow out the bottom of the master cylinder assembly, drill the hole bigger on the lug, or reduce the circumfrence of the lug. I choose the last option as it had the upside without the downside. I only needed to shave off an 1/8th of an inch so the structural strength was still there. I took my time and shaved off a little, deburred and smoothed it and then tried the fit again. I did this a few times until the left master cylinder fit and moved like the right one. All good - both brke master cylinder bottoms attached.
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right one is good

right one is good

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hard to see a difference, but the left is off a bit

hard to see a difference, but the left is off a bit

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