Oct 28, 2023     Forward rudder pedal position - (1.0 hour)       Category: 38: Rud Pedals

Although I plan to use the aft rudder position, I realize it is probably better to go ahead and do the work now to accommodate the forward position in case I get taller some day. I had previously run the crossover brake lines below the center support and realize now that they'd be in the way of sliding the pedals back. Thankfully the hole I drilled for the adel clamp is exactly where it needs to be for the rear rudder position.

So unbolted everything and slid the side support brackets back to the rear position. The match drilled the center support block in the rear position. Ran the crossover cables above the center bracket and drilled a hole through the too flange. Decided to install a nut plate to maybe make it easier to remove in the future. Maybe. It's going to be very tight up in there but at least now you'll only need to get one wrench on it and not two.

That's it. Can disassemble it all now and prime a few parts.

  Oct 20, 2023     38-6 & 7: TS Flightlines brake lines - (2.0 hours)       Category: 38: Rud Pedals

My general rule of thumb is that I'm not going to pay for things just to reduce my build time. I was happy to bend the hard brake lines through the tunnel and under the seats, but the stock configuration of flexible nylon hoses between the brake pedals seems pretty cheap and likely to leak some day. So I did splurge a little for the stainless steel braided hoses from TS Flightlines, just for the hoses between the pedals, and they arrived this week.

Was very pleased to see the included all of the AN hardware needed for the master cylinders and the reservoir. The hoses are varied in length and there are not any instructions provided so it took me a minute to figure out which hose goes where. Once I got that sorted out though the installation was very easy.

Loosely installed the AN fittings in all places, will need to come back and seal the pipe threads and final tighten. Then connected the hoses to confirm the routing. The two holes in the center rudder support bracket don't work well for these lines so you either go over the top of the bracket or below. Was going to go over, but the top flange of the bracket isnt really wide enough to drill and install an adel clamp to hold the hoses. So I went under and secured both hoses with two clamps and a single bolt.

Tidied things up with a few tie wraps and checked the motion of the pedals and brakes. Clearances are good.

Will not final torque anything yet. This whole assembly need to come out when I paint the interior. But it's done for now.

Also went ahead and springs on the master cylinders to help them fully extend and not drag. It's a common modification and I got the McMaster-Carr part numbers off another builder's log. Part numbers in image. All went together pretty easy, but the springs are a little firmer than I wish they were. We'll see.

  Oct 16, 2023     38-8 thru 38-10: Running the rudder cables - (3.5 hours)       Category: 38: Rud Pedals

Wow, what a pain. Tried to get my son to crawl in the back of the tail cone to run rudder cables but he couldn't get the spade on the cables through the snap bushings. Ended up crawling back there myself and was able to get it. But of course the first try ended up with the cables twisted and had to redo it. I think I was in and out of the tail a total of three times. Each time more awkward than the last.

Finally got them run all the way to the front and then installed the adel clamps in the rear and the adel clamps at the front tunnel exit.

10/22: fabricated the links and primed and then installed them. Drilled the holes in the nylon cable guides and then match drilled them to the tunnel ribs. Installed. When fully tightened, they are a bit too tight in the cables, so backed off a little. Need to play with that later.

No cotter pins installed yet, all of this needs to come apart later when I paint the interior.

  Oct 15, 2023     38-2 thru 38-5: starting in rudder pedals - (2.0 hours)       Category: 38: Rud Pedals

Trying to get everything that needs EkoPoxy prepped and ready to prime,so I'm skipping ahead a little bit.

I had previously prepped the rudder pedals and brake master cylinder brackets so finally it was time to river eat the doublers to the pedals. Based on the diagram in the plans, I misinterpreted which was the front face of the pedals and installed all the rivets backwards. I will need to drill them out and redo.

Drilled the center support block per the plans and cut it in half. Match drilled the side support blocks. Bolted everything up and match drilled the center support bracket.

Always knew that I didn't want the stock nylon brake lines. Ordered just the firewall lines and gear leg line from TS Flightlines. Also ordered hardware for McMaster Carr to install springs in each master cylinder to prevent brake drag. I may convert to the single bolt pedal support, but those long bolts are $25 a piece! May hold off on that for now.

10/15: got the pedals all drilled out and re-riveted. Then installed the pedals and brake master cylinders. Looks pretty slick and everything moves freely.