Today after doing my chores I started the pedal extensions. I have seen a few sites where builders have made extensions. It seems there a couple of ways to keep from adding brake pressure when taxing around. With the current design it is near impossible or so I have read, to apply rudder pressure without adding some brake pressure. You end up with hot brakes and in some cases hot enough to melt the seals and start a brake fire. Since I plan to fly to a lot of fly-ins and there are some extended taxi times at them, I wanted to solve the issue while I am building. Some put a steel rod at the brake pedal pivot point; this lets you apply rudder pressure without moving the brake pedal. My feet are so big I thought I would copy the pedal extension idea. You rivet on a section of aluminum to extend the pedal down, this gives a foot rest below the brake pedal pivot point, you can also put your heel on the extension for the times when you need brakes and rudder deflection at the same time, which is needed with the nose wheel RV’s.
I first made a cardboard proto type to make sure things would clear and not interfere with the pedal operation. I then cut out the two extensions from a sheet of .125 - 2024T3 aluminum. I read others used this thickness. I then smoothed the edges and marked the bend line, or at least where I figured it should go. The bend is the tough part. I tried holding the part between two pieces of oak, one side with the radius I wanted but when I try to bend it all I am getting is a curve. So I left it for the night, I plan to make another blank and then try to find someone in town that has a bending brake and see if that gives me the bend I want. I do like the fabrication and design part, although I am just copying another idea.
