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Date:  7-28-2017
Number of Hours:  9.00
Manual Reference:  DWG C2
Brief Description:  Installing the Main wheels and brakes

The drawings for the mains don’t have a parts breakdown and it’s not intuitively obvious how the parts all go together. Additionally, the written instructions are incorrect. Having said all that, I’m glad a bunch of other guys have done this ahead of me. After spending nearly 3 hours trying to figure out a very simple system, I went online and saw how the ‘real’ builders did this. I have the 199-10200 5.00x5 Cleveland brakes and the wheel hubs already have the bearings packed with Aeroshell #5 grease. The brake mounting flange was honed and drilled at the factory to fit the axle but I had to finely sand the inside to flange and the axle as well as grease both to get the flange to fit. The first picture is re-drilling the U-403 brake flange to 5/16”. I also pressed the brake torque plate onto the U-403 brake flange in my vice between a couple blocks of wood. On the right brake, the powder coating on the brake flange was too thick so I had to sand it off, press on the brake torque pate (flipped backwards from the left side) and repaint the whole assembly with enamel paint to prevent corrosion. Next, I made the (6) U-408 spacers from 3/8 x .6061 T6 Tubing. Before I attached the U-810 Fairing Mount, I installed the (4) K1000-06 nutplates. Next I installed the U-810 Wheel Fairing Mounts using an additional AN 416-960 washer to get the correct 1/16” clearance between the U-810 and the brake disc. Finally, I installed an AN-822 Elbow, nut and sleeve for the brake fluid line that goes to the reservoir. Then I slid the whole assembly ono the gear leg and bolted it to the leg with the 5/16x20 1 ½ Allen-bolt and torqued to the proper tightness. The brakes are mounted with the caliper aft of the axle, and the bleed nipple facing down. When you tighten the VA-106 Nut which holds the wheel onto the axle, you have to make sure there is no side play in the wheel, but it still rotates smoothly. The final step to the assembly is to center punch mark the position of the cotter pin hole in the axle, remove the nut and
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Drilling U-403 brake flange

Drilling U-403 brake flange

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Flange Bolted to U-810 Fairing Mount

Flange Bolted to U-810 Fairing Mount

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U-810 w/ plate nuts and paint

U-810 w/ plate nuts and paint

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