I started today be measuring the existing rudder pedals in the aircraft. They confom very closely to the plans. This is good as it means I will not have to correct their width to add the toe brake installation. I then determined from the toe brake plans the length of the cross tubes for the toe brake pedals. They should be 4.185" if the side pices are ,060" thick. I cut 2 tubes as square as possible to this length and cleaned them up with a belt sander and a Dremel tool. Next I jigged the large end and the tube togther for each assembly and mig welded them together. It is best to tack weld them and then check for squareness. Mine worked out fine. I then cleaned up the edges a bit so that they would sit flat on the table and set the small end up to be welded into place on each pedal. They were also mig welded together. I cleaned them up using my angle grinder and a flap wheel for the main work. It is important for clearance to make sure the outside of the flat steel pieces have no welding slag or weld bead to interfere with the assembly when it is put in the plane. The drawings show very little clearance at times. If you decide to add these you must make a left and a right unit. I finished today with a mock up of the control strips that tie the pedals to the brake cylinders. It appears that extra washers will be needed at the pivot points to take up slack. This is a slight error in the plans from the Barracuda Builders group on Yahoo. The finished pedal are within .010" of identical to each other. Good enough for sure! One is .006" short and one is .004" long. I had to measure them with a calipers to find that difference.
