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Michaels Web Site
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Date: 7-8-2012
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Number of Hours: 2.00
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Manual Reference: L01
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Brief Description: Gear legs and brakes
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In doing the first gear leg yesterday, getting all the holes aligned between the gear leg and both sides of the engine mount tube, I decided to do it a little different for the second leg.
- With the gear in the engine mount (laying on my work bench), I used the cobalt bit to start the hole in the gear leg (photo #1). This gave a better actual alignment of the hole. Yesterday I only made a mak with the tip of the drill bit, then did all the work on the drill press. Problem was, even with the centering jig those first millimeters of drill bit bit are critical to where the hole will actually go. So by doing it this way I had a good 1/8" of hole started in the gear leg by the time I pulled it out of the engine mount.
- Now I put the gear leg on my drill press with the centering jig again (see yesterday's log) and slowly drilled through the leg.
- After removing the burrs I put the gear leg back in the engine mount, aligned it with a sacrificial 1/4" bolt, and then CAREFULLY used the 1/4" cobalt drill bit in my hand drill again (just like in photo #1), to drill out the other side of the engine mount tube that holds the gear in place. This whole scenario turned out much cleaner and better aligned than yesterday's event.
- Next I bent the LEFT brake lever arm. Sonex ships 2 right-handed arms, so you need to manually bend it in the opposite direction. There are just 2 bends, and after putting it in the vice and using a plastic mallet, I got the required bends in just a few minutes.
- Now I tried to work on the brake shoe pins, which need to have some edges filed down. But to do so you need to separate the two shoes which are held together by 2 VERY strong springs. I tried to do it with various tools I had on hand, but I could not get them spread far enough. So I need to go to a plan B.
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With the gear in the engine mount, I used the cobalt bit to start the hole in the gear leg.
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Brake arm being bent for LEFT side use.
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The brake and axel assemblise laid out.
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