Jan 24, 2024     38-3 Beringer Brake System Brake Lines Torque - (3 hours)       Category: Brake System

FInal torque of the banjo bolts and all the fittings.
For the Banjo Bolts i used the tecnique indicated in the maintenance documentation provided by Beringer (torque to 44Lbs/in and then torque another 90 degrees). (from 5Nm adding 90 degrees the end torque is 27NM, 10 Newton meter more than the indication found in the Beringer RV10 installation manuale that indicates max torque at 17Nmeters).

  Dec 14, 2023     38-3 Beringer Brake System Re-Routing - (4 hours) Category: Brake System

Completed new rerouting of Beringer Brake lines. Shortened two lines for the new routing. Final install of the Brake Fluid reservoir and steel Tee. Final torqued the braided line fitting. Two different information, first one in document mm-00-005_-_tightening_torque_2.pdf indicating to torque up to 0-1 thread visible. The Beringer RV10 installation manual indicates a different procedure for braided fitting torque (90-132 lbs/in, 10-15 N/m)

  Dec 05, 2023     36-3 Brake Lines MOD Parking Brake - (3 hours)       Category: Brake System

Lucio prepared a bracket for the parking brake using aluminum angle. Using nutplates and an3 bolts installation looks stable. Primed the parts. Final torqued the parking brake hardware and all the bolts securing the pedal delrin blocks to the fuselage longerons.

  Nov 30, 2023     36-3 Brake Lines step 3 - (3 hours)       Category: Brake System

Lucio had to reproduce the left brake line as it had been damaged during firewall drilling. On the second attempt the line clears all the obstacles.
Final installation up to the firewall bracket. Torqued the bulkhead fitting at the back tunnel and all the fitting up to the firewall bracket.
Final installation of all the clamps.
Firewall nut plate holding the clamp for both lines had the screw protruding through he fiberfrax. Added to large washer and a metal lock nut in order to hold the fiberfrax (shear nut would be sufficient).

  Nov 30, 2023     38-3 Beringer Brake System Parking Brake - (1 hour)       Category: Brake System

Removed parking brake valve. Lucio prepared a bracket to hold the control cable using Aluminum angle.
Parking Brake Valve will be covered by the bracket therefore i attach here a picture with all the scribed informations.

  Nov 05, 2023     38-3 Beringer Brake System - (1 hour) Category: Brake System

Repositioned the ALIR differential brake regulator. Unfortunately some interference with the new left brake tube.

  Sep 26, 2023     38-3 Beringer Brake System Re-Routing - (1 hour) Category: Brake System

Another attempt at rerouting and recutting the reservoir-copilot brake lines. The new lines are running in front of the pedal instead of running behind. With this new configuration i see less tensions on the reservoir Tee connector.

  Sep 12, 2023     38-3 Beringer Brake System Re-Routing - (2 hours)       Category: Brake System

I decided to mark the different hoses using heat shrink printer. Installing the heatshrink has been a bit of a nightmare, but finally i succeeded.
Only thing to do is to torque all the fittings and check for leaks when the wheels will be installed.

  Sep 11, 2023     38-3 Beringer Brake System Re-Routing - (3 hours) Category: Brake System

I had to remove pedal and brake assembly in order to install long bolts on the pedals.
After installing the long bolts AN3-57, castle nut and cotter pin i reinstalled the pedal assembly and the brake lines. I am still fully satisfied with the brake fluid reservoir connection, as it seems that the brake line are putting tension on the brake reservoir tee.

  May 06, 2023     38-3 Beringer Brake System Re-Routing - (4 hours)       Category: Brake System

Tested different alternatives for the Beringer routing. I didn't like the routing below the cylinder and checked a different configuration having both lines going in parallel in front. I checked on the web and there are only few using this setup. Majority uses the recommended routing (both VANS and Beringer) with the lines going behind the cylinder.
I went back to this approach, changing a bit the tying position (three zip ties for the hose behind the cylinder) in order to minimize the movement. now it looks pretty solid. It is not final yet.
I decide to install three nutplates instead of the initial set-up with classic bolt and nut. Reason being that once the fuselage forward top cover will be riveted maintenance will be easier with the nutplates instead of the normal bolt/nut.

  Apr 03, 2023     36-2 Brake Lines step 1-2 - (3 hours)       Category: Brake System

After checking with Lucio it seems that the brake lines are running too close to the new landing gear mount and in addition the curves are too sharp.
I scrapped the old lines and i bended the lines again with more clearing space and with smoother curves.

  Jan 21, 2023     38-3 Beringer Brake System - (2 hours)       Category: Brake System

Rechecked the hose runs. Rearranged few runs to better accomodate rudder pedal movement and reducing friction.
Installed heat shrink tubes in likely friction spots.
Temporary install of the solid aluminum tubing support flange.

  Jan 19, 2023     38-3 Beringer Brake System - (2 hours)       Category: Brake System

Fabricated a support for the 6 hoses using a nylon bar 2cmX1cm. Drilled three holes and matchdrilled on the aluminum support.
Prepared the missing hoses and cut to measure.

  Jan 18, 2023     38-3 Beringer Brake System - (3 hours)       Category: Brake System

Reinstalled the Rudder Pedal assembly. Measured and cut the missing hoses.
Temporary install of the ALIR regulator below the central rudder pedal support as indicated in the Beringer Assembly instructions.

  Jan 17, 2023     38-4 Step 1-6 Rudder Pedals and Brake System - (2 hours)       Category: Brake System

Reinstalling the Rudder Pedals using correct bolt length. One of the delrin blocks had an enlarged hole, therefore i replaced it with a new DELRIN Ruder Pedal block after drilling the holes correctly.
I also installed the parking brake assembly using slightly longer bolts and modified washers to clear the longeron flange on both sides

  Sep 10, 2022     38-3 Beringer Brake System - (6 hours)       Category: Brake System

I decided the purchase the anti skid regulator from Beringer (ALIR). The recommendation is to install below the middle pedal bearing. Unfortunately the support provided by Beringer works only if the pedals are mounted in the most rear position. As i am 1,83 cm tall, i prefer to install the pedals as indicated in the plans in the most forward position.
I tried to position the ALIR regulator on the left side, below the pedal bearing as indicated by other builders, however operating the regulator was impossible for me.
I resolved creating a new support. First try with a 3mm aluminum, but the result was not satisfactory. I used a normal 2mm aluminum and i am pretty happy with the result. Especially considering that my band saw is broken and every attempt to repair miserably failed.
I test installed before priming and painting. Final install still to be done.
There is enough clearence from the firewall and from the aluminum brake lines.

  Jul 10, 2022     38-3 Beringer Brake System Reservoir - (2 hours)       Category: Brake System

Installed the reservoir provided by VANS.
Cut the tubes according to indication. Installed the adapter and the Tee to the reservoir.
The pipes seem to be a little bit short and i think there is a little tension on the tee...maybe the reason is that the banjo bolt are still finger tight and the banjo is moving around.
In any case i checked with other builders and the solution to route the IN Pipes (bottom banjo on the cylinders) below and behind the pedals is the most adopted.
I used temporary tie wraps to secure the tubes while waiting for the beringer pressure controller and for Lucio's inspection

  Jul 09, 2022     38-3 Beringer Brake System - (3 hours)       Category: Brake System

While waiting for the last component (regulator) i prepared the pipes linking the copilot brakes to the pilot brakes as indicated in the instructions.
I decided to run the pipes on the pilot pedals under and behind the cylinder, then along the two pedal tubes and into one of the lightening holes of the pedal assembly bracket.
I didn't final install, the banjo are not torqued and the zipties are only temporary in order to check if everything will be fine once all the component will be in place.
I need to buy the grommets to protect the pipes in the lightening holes

  Jul 09, 2022     38-3 Beringer Master Cylinder Assembly - (2 hours)       Category: Brake System

CAUTION USE ONLY MIL (MINERAL) brake fluid (MIL-PRF 8257 or MIL-PRF5606)
Installed banjo bolts on OUT line for all cylinders. Torqued to specification 17Nm
Torqued all the nuts
Marked yellow all torqued items
Checked length of all the cylinders

  Jul 06, 2022     38-3 Beringer Brake System Parking Brake - (12 hours)       Category: Brake System

Removed the MATCO parking brake valve and reinstalled the F-6221-1 Tri-gear Bracket with flush rivets according to section 27 Firewall.

Assembled the Beringer Parking brake valve.
Installed the Banjo Bolts and the straight banjo fitting.
Torqued the Banjo bolt to 17N/m as indicated in the Beringer Torquing instructions
The rudder pedal bearing blocks have been removed and reinstalled few times as i needed to grind the washers on the front bolt in order to clear the F-1013L/R as indicated in the Section 38-4.
I also prepared the two hoses from the Tri-Gear bracket to the Parking brake valve as indicated in the Beringer Manual.
Torque for the hose socket is indicated by Beringer between 10N/m (90lbs/in) and 15N/m (132lbs/in)



NEED to REPLACE all the Bolts on the rudder bearing blocks with longer ones. This is due to the use of more washers and to the installation of the parking brake bracket and brake regulator bracket.

  Jun 26, 2022     38-3 Beringer Master Cylinder Assembly - (2 hours)       Category: Brake System

As i decided to install the Beringer Brake kit for RV10, which includes new master cylinders, new parking brake valve, new braided tubing and the pressure regulator i had to remove the original MATCO VANS master cylinders and assembly the new BERINGER master cylinders.

Beringer Master cylinders need some final assembly work. Installation on the pedal sub-assembly is a bit tricky as the drawing doesn't consider the pedal master cylinder attach flange and the washers seem to be a little bit scarce in order to have perfect alignment. However i liked the bushing provided and the ball-end bushing and in general the higher quality of the parts compare to the standard MATCO cylinders provided by VANS.

Altough Beringer is suggesting to use normal nylon lock nuts, i believe i will use castellated nuts and drilled bolts as suggested in the original VANS setup.
I spent a couple of hours on the first master cylinder as i had to figure out the most appropriate washer combination.
Picture are still showing preliminary assembly with short drilled bolts....will replace before final assembly.
Assembly of the next three will be definitely quicker.

Master cylinders from beringer come in two versions. One for DOT4 brake fluid and the other for MIL Mineral brake fluid. MY VERSION IS THE MS-002N (MIL Mineral FLUID).

  Jun 19, 2022     36-3 Beringer Kit Inventory - (2 hours) Category: Brake System

Received the Beringer kit containing the wheels, brakes assemblies, parking brake assembly and brake cylinders assemblies. Ordered the brake regulator.

  Aug 04, 2021     36-3 Brake Lines MOD Parking Brake - (3 hours)       Category: Brake System

I have been thinking for a while on creating a support for the two brake lines in the area of the firewall recess. I personally don't like the two brake lines hanging for such a long trait between the two clamps close to the air vent and the parking brake assembly.
I decided to use a relatively thick aluminum angle to create the support to be riveted to the F-1039D rudder pedal brace.
The angle will have also a nut plate to hold two clamps, one for each brake tube. This will allow rapid disassembly if necessary and a stable support avoiding the brake lines to rub against each other or against the rudder pedal brace.
The first attempt proved that the idea was ok, but i decided for a second design with more "beef" to rivet the brackets to the rudder pedal brace.
Final assembly will happen after replacement of the firewall recess in order to position the new steel passthrough.

  Aug 02, 2021     36-4 Step 1 Brake Lines - (0.5 hour) Category: Brake System

Prepared the VENT DL-10 2,4" flanged ducts for installation. Clecoed only and final riveting will be completed at the end of the installation of all the systems.

  Jul 09, 2021     36-3 Brake Lines MOD Parking Brake - (2 hours)       Category: Brake System

Assembled the parking brake valve and installed on firewall.
Mounted the Parking Brake bracket using pull rivets as indicated in the modification instructions and with loctite 567 provided in mod kit.
Installed the bluefitting with permatex 2.

  Jan 10, 2021     36-3 Brake Lines step 1-6 - (9 hours)       Category: Brake System

Removed the vent flanged ducts. Created the brake lines (few attempts required). I started bending an aluminum bar to get an idea about the different angles and then once bending was satisfactory i replicated with the tube bender. The end result is good and the lines look straight and with the right bends.
I decided to install a parking brake, therefore i will need to remove the trigear bracket and replace with the valve and controls for the parking brake.

  Jan 09, 2021     36-2 Brake Lines step 1-2 - (1.5 hours)       Category: Brake System

enlarged both holes in the bottom skin to 5/8" for the An837-4D elbow. Installed the elbow on both sides. Prepared the brake line bending the aluminium tube and flaring on both sides for the elbows.

  Jan 03, 2021     38-2 Step 1-6 Rudder Pedals and Brake System - (4 hours) Category: Brake System

Separated the rudder pedals, created the spacers from the A&-058X5/16 tubing. Final drilled #30 and deburred all edges and holes. Riveted the master cylinder attach to the pedal assembly