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Kupe's Zodiac 650B
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Date:  4-30-2015
Number of Hours:  1.00
Manual Reference:  
Brief Description:  Brake Lines - Start

Started laying out the brake lines today. There are several challenges to this that I have been mulling over for some time so today I started really imagining how the lines will travel from the pilot-side rudder pedals, through the aircraft, and down the landing gear to the brakes. The combination of limited space and lots of other moving parts (like control cables) adds to the challenge. Here are the issues I've been considering and my solutions so far:

- Brake line routing past the wing spar: With a choice between along the inside sides, along the outside bottom (along the lower longeron) or through the center hole of the wing spar, I chose the latter. Challenge: Rudder cables run through there as do the elevator cables just aft of the spar. Eventually some of the wiring/pitot-static hoses too.

- Where to have the lines exit the fuselage: I chose under the respective seats. There are inspection panels in the bottom of each seat which is good, and outside the aircraft at that point will be inside the wing root (i.e. protected).

- What about a parking brake? Short answer: Yes. Matco has a nice, portable brake - now I only need to figure out where to mount it.

So, the plan is to have the brake lines exit the two pilot-side master cylinders to the right where they will head aft along the center of the cabin floor. Just aft of the rudder pedals, on the heel support, I will mount the parking brake which will be controlled by a ratchet control cable with a pull-to-lock knob on the center console. Before and after the parking brake, the lines will be secured with adel clamps as well as after the pass through the center hole of the wing center spar. At that point the lines will split left and right under the seats and exit the cabin near the outer seat belt attach points. The lines will run aft along the fuselage to the aft gear bolts then run down the aft edge of the main (spring) gear to the brake housings. The attach method along the spring gear is still being researched
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The key parts of the brake system laid out for planning.

The key parts of the brake system laid out for planning.

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