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Larry Winger's 601XL Project
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Date: 4-1-2008
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Number of Hours: 3.00
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Manual Reference:
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Brief Description: Mounted brake pedals
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I tackled the brake hinges and pedals tonight, and they were actually more challenging than I anticipated. I had two full sets of hinges from ZAC and one set from Tom Henderson. As it turns out, I needed all of them. The first one from ZAC I ruined because I drilled my holes in the center of the hinge, which doesn't take into account the need to bring the hinge line in contact with the radius of the tubing. By drilling the holes in the middle, it caused the hinge to teeter in both directions, instead of being flush at the top and ready to curve to the radius below. The other thing I noticed (too late) is that the plans call for a 40mm hinge opening, but the part they supply is 50mm wide. By leaving it 5mm wider (per side), it requires more hammering and bending to get the hinge flange to conform to the tubing. That is too much work and very difficult to do well. So two ZAC hinges were toast. I trimmed the other ZAC hinges and did them correctly. I also pressed the Henderson hinges into service for the passenger side. The other thing I did and would recommend was to buy a short length of 1/2" black pipe at Home Depot to begin the bending process on something that I wouldn't mind clamping in the vice. When I transferred the bent hinge to the rudder pedals, all I had to do was minor tweaking. Word to the wise -- stock up on drill bits. I broke or totally dulled four #40 drill bits tonight. That is more than I've gone through in 6 months of working with sheet aluminum and aluminum extrusion. The rudder/brake geometry was always unclear to me, but it all came together tonight. It was very cool seeing how the brake pedals all remain slightly tipped back, no matter what the angle of the rudder pedal. Pretty clever design by Chris Heintz and all the rudder/brake designers that have gone before him.
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Everything in place
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All lined up...which will never be the case once the rudder cables and steering rods are rigged.
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The brake pedals remain parallel regardless of position
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