Monday July 25th, 2005|
Finished Rudder Pedals; Started Drilling Floor Stiffeners
Today I went out and mounted the rudder pedals in the plane. The plans call for a minimum distance of 3 inches from the firewall to the UHMW blocks that hold the rudder bars...so I marked the location of three inches on the stiffeners and removed the stiffeners from the fuselage. On the bench I measured out the desired pedal locations by referencing the marks. I'm only going with two adjustable positions. I don't see a need for any more. I'm 6 foot tall...and I'm building this plane for me....so there you go. Most folks tell me they prefer the rudder pedals all the way back anyway.
Here you can see how the blocks bolt into the stiffener.
This is the rudder pedal brace as it comes from Van's.
...And here's the drawing for the brace. You can see here that there's a block that sits midspan (actually to the left side of the firewall recess) on the bars that adds support. The positions here are completely relative to the mounting holes you made on the stiffeners, so you basically mount the bars in each location and match-drill the holes to the brace.
Here you can see the brace has been drilled at both locations. You can probably also see that the rudder brace extends a bit past the the aft-most mounting location (more on that later).
Here's the big picture (I rotated this picture so you can see it upright). You can see the rudder brace in the top center of the photo..just to the left of the firewall recess hole.
In the drawing up higher on the page...you'll see where the plans allow you to trim the brace down if you're not using the full length of it...so I marked the lines where I wanted to cut it.
Then I cut the piece out and make some lightening holes. I actually spent a bit too long doing this. Since the drawing only shows you the lightening holes to use if you're using the full length of the brace, you're more or less at a loss here on how to make the holes. So what I did was try to gain some logic from the drawing. In the drawing...it appears that they use equal edge distance on both the top and bottom of the piece...so I used the same edge distance. Also, they appear to use constant spacing between the holes...so I did that too. I drew a bunch of lines and used some Euclidean geometry (and actually used the sin and cos buttons on my calculator) and came up with the correct diameters to use. I think it came out rather well. I used a fly cutter on the two larger holes and a unibit on the smaller hole.
And here it is clecoed back into position.
After taking this picture, I was laying in the floor on my back looking up at this stuff and I fell asleep.
...after an hour nap on the floor (no kidding) started working on the floor stiffeners. I started out by marking centerlines along the bottom flanges.
..and here you can see where the stiffeners have been drilled.
This is the center channel that runs along the floor. This is how fuel lines and electrical make it back into the control sticks, aft fuse, etc. It gets wedged between the stiffeners and will eventually get drilled for screws that hold it in. I put it here just to check my spacing of the stiffeners to make sure that everything goes together well....yep....looks good.