Jan 02, 2024     Aileron support bracket and Bellcrank - (16 hours)       Category: Controls

The positioning of the aileron bellcrank and bearing is dependant on the wing and specifically the rear spar. I wanted to weld, so I started searching the garage for my raw materials, cutting pieces to size. Once everything was sized properly, I broke out the TIG. Welding is becoming my favorite task. Some minor fit and finishing work, and everything looks as it should.

  Oct 15, 2023     Controls and instrument panel - (8 hours)       Category: Controls

Playing around in the garage. Had a temp wood mock up to hold the bearing support for the control yoke. Replaced with a proper piece of angle aluminum and support to hold the bearing mounts. The IP will be in front of this and will be supported top and bottom. A previously used scrap of cardboard supports cut outs for the panels for AHERS, Navigation and EIS. The EFIS and Nav will be interchangeable via wi-fi connectivity and allow for passenger participation as well as I pad failure. Seats are re-installed to check on overall ergonomics and reach.

  Jun 16, 2023     Aileron control cables fabricated - (16 hours)       Category: Controls

Started working on the aileron cables several months ago. First order was creating the non standard routing for the cables, as I am using a fabricated control yoke. Once the installation of the pulleys (not final, just for fabrication purposes) was completed, I began to fabricate the cables. Getting turnbuckles was a challenge, but I did eventually find some. The fabrication of the cables was straightforward. The only challenge was the pass through from the aileron bellcrank to the return line under the passenger seat. It is very close, and the hardware from the cable is close to contacting the structure. This is only at the extreme deflection, that will most likely not be achieved when the ailerons are installed. Adjustments will be necessary with the final rigging.

  Nov 20, 2022     Final layout of Control column base - (8 hours)       Category: Controls

Working in the Garage this weekend. I had mocked up the location of the control column and the location for the pulleys that will transfer the motion of the turn on the yoke to the up and down needed for the ailerons. I installed nutplates to allow for the complete removal of the control yoke. I have installed it in it's permanent configuration. I will be removing it several times as I install other components and riveting in the floor, rudder pedal support, firewall, brakes, and other support structures in the instrument panel area.

  Nov 02, 2022     Control construction update - (40 hours) Category: Controls

I have been working on several components of the control system. There are 3 Major components: Aileron controls via the control yoke, Elevator controls also with the control Yoke and the Rudder controls via rudder pedals. I will discuss the progress of each of these areas.

Aileron: I have completed the fabrication of the core elements of the cable system located horizontally in the cockpit. These consist of the control yoke, pulleys that take the control cable from the yoke to the base pulley, through the landing gear box, outward to the sides, back to the lower aileron bellcrank, then back to the connecting return to the other side. Pulley mounts and brackets have been held in place with clecos. Only cable guards on each pulley need to be made with the control cables.

Elevator: A bracket was welded to connect the forward elevator tube to the control yoke. This bracket was required to lower the angle of the tube. The aft portion is connected to a "swing" to transfer the for and aft motion toward the rear of the aircraft. Brackets and bracing hold the "swing" in place, The Forward and the portion of the aft tube in the passenger compartment will be eventually covered by a tunnel fabricated from sheet aluminum. This will also form an armrest and center console for gauges and engine controls.

Rudder: Cables attatch to the inner portion of the rudder pedals adjacent to the control column. The cables will travel inside the tunnel under the swing and to the aft of the fuselage. A rudder bellcrank has been fabricated and secured to the rear of the fuselage. The cables are guided to the rear by micarta guides and connect to the rudder via a control rod attached to the rudder bellcrank.

  Jul 12, 2022     Aileron control cable routing - (4 hours)       Category: Controls

Control column connection to aileron cables. Locating the pulleys at the base of the column was not obvious to me, but as soon as it was placed, the routing became obvious. I will use yellow mason line to visualize the route for the cables, through the landing gear box, out to the sides of the fuselage and to the lower aileron bellcrank that will move the aileron control rod to push the upper aileron bellcrank.

  Jul 12, 2022     Horizontal Stabilizer Bracket - (16 hours)       Category: Controls

I have fabricated the bracket that attaches the Horizontal Stabilizer to the fuselage. I originally started with a flat piece of 0.040 plate, progressively bent it into a half circle with flanges at each long edge. It was very difficult to get the multiple bends square and ultimately it yeilded a substandard part. I then went to the auto parts store and bought the appropriately sized exhaust pipe, cut it slightly longer than in half, welded the brackets to it and then bent up the edges to create the flat flanges for attatching to the spar of the HS. The first try using the TIG welder ended poorly as I burned through each piece of metal and appliied too much heat, warping each part. I then turned to my flux core wire fed welder and had much better success. I was able to acheive full penetration and a very secure attachment of brackets and tabs. Heat was controlled and the part fit. I found some adjustments were necessary, but I have secure and free movement.

  May 02, 2022     Drawing control system routing - (2 hours)       Category: Controls

Control yoke has been located in forward fuselage along with rudder pedals. Now it is time to plan routing of aileron and rudder cables as well as the pushrod that will control the horizontal stabilator.

Aileron: I have modified the routing due to the use of my control yoke mounted near the firewall forward of the Landing Gear Main (LGM) box. There are two pulleys mounted at the base of the yoke, directing the control wires forward to the base of the forward side of the LGM. Two pulleys there send the wires through the LGM to the aft side, where two more pulleys direct the wires out to the sides of the C-channel. Two additional pulleys direct the wires aft, to the corner posts, at the base of which will be a bellcrank directing the forces upward via a pair of control rods to the Aileron belcrank. A connecting wire will continue aft from the lower bellcrank, turn inward by a final pulley to close the loop. A turnbuckle will be placed between the 2 aft pulleys to adjust tension.

For the rudder control, the cable will attach to control arms on each rudder pedal assembly. These are outside the control yoke base, approximately 6 inches apart. They will be routed to the base of the forward side of the LGM and using pulleys will be sent to the rear of the LGM. Pulleys there will direct them toward the center approximately 2 inches apart. The cables will continue rearward and to another set of pulleys that will direct them upward along the bottom of the empanage to the Rudder Bellcrank. Here they will control the rudder as well as the tail wheel.

Horizontal Stabilator: This is manipulated by a control rod from the mid point on the control yoke shaft. The shaft is angled downward to run along the top of the LGM and aft toward a bellcrank within the center tunnel between the passenger seats. From the bellcrank, another control rod will connect to the Horizontal stabilator bellcrank at the rear of the fuselage.

Preliminary measurements and locating the pulleys will be done prior to making the bellcrank and pulley brackets. The bellcranks are weldments that will be produced later.