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Builder Name:Patrick Bruce   -  
Project:   Bearhawk - Patrol   -   VIEW REPORTS
Total Hours:593
Total Flight Time:5
Start/Last Date:Mar 02, 2023 - No Finish Date
 
Friendly URL: https://eaabuilderslog.org?s=pbruce

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Apr 30, 2020     Flap cable pulleys - (4 hours)       Category: Fuselage
The flap activation system uses a Johnson Bar style handle (like a 185 or cub) which pulls a cable which is routed through a system of 7 pulleys to the flap actuator arm at the wing root, and from there via a torque rod and pushrods to the flap.

Each pulley must be bolted onto a 1/4” tube which is welded onto the fuselage frame. They also require a cable guard so the cable can't skip off the pulley. The pulley guards are not provided for the fuselage pulleys, so I have to make them. I got some 22 gauge sheet steel at Lows, and also a $30 bending brake at Princess Auto seen here sitting on top of my jointer. (I will need it for other jobs including LE skin stiffeners). It works really well. I cut, bent, and drilled the first three pulley guards. They require a method to prevent rotation and subsequent jamming of the control cable. For the first two at the wing root, I elected to lock wire the pulley guards to the mounting tube using a cross-pattern. I tested the system with the bolt loose and it works. I doubled up with two independent lock wires. It doesn't look elegant but it will work. On other pulleys I will try to fashion a leg which can be secured to a tube to prevent rotation. I wrecked quite a few In the making because the tolerances are tight and I was unable to replicate the first one exactly. Small cheap pieces, but a big expenditure of time.


 


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