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Rob's REBVAIR Project
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Date:  5-2-2016
Number of Hours:  6.00
Manual Reference:  
Brief Description:  Servo bracket install

I'm following Ron Shannon's approach to securing my GRT roll servo to the floor in front of the bellcrank.

Not much to say about the fabrication; the pictures tell the story. A 0.063" Z-bracket (again done on my trusty DIY brake) was bolted to the main cross-member on the floor to provide the vertical support for the 2.5 lb servo. This is further braced with a diagonal brace down to the bellcrank support. Then there's a 0.050" horizontal gusset which braces against the forward lower corner wrap which also has a brace (not painted) to provide vertical support.

Servo is nicely immobilized when I push or twist horizontally (direction of the forces when the servo is in operation), but I still need to be mindful of stepping down on the whole thing, hence the striped 'high-viz' color scheme. Rigidity here is so critical because of the signifcant torque this servo has to exert to move the ailerons...it has only a fraction of the leverage that I do with the control stick.

The vertical positioning was dictated by the full height from the right-angle D-sub connector all the way to the top of the servo arm (about 5.25"). I knew from Ron's installation that this could be made to work, but the 5/16" diameter pushrod (not yet installed) will need to sit on top of the bellcrank and under the servo arm to accommodate the alignment between the two pivot points. The whole apparatus sits proud of the fuel line, and below the rudder cables. Again, seeing Ron's installation took most of the guess-work out of this installation.

All the AN3 attach hardware is drilled for safety wire. The push rod is from GRT, essentially a 3/8" solid aluminum solid drilled to 10-32 on one end, and 1/4-28 on the other.Clearances are pretty tight all around...0.63" between the bolt head on the servo arm and the brackets.

Now I can set the ADS-B antenna location, drill the hole for the brake lines, and install a kick-plate to further protect the area.
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outboard corner of pilot's foot-well

outboard corner of pilot's foot-well

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horizontal view

horizontal view

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