Thursday, September 27, 2012

Vans Aircraft RV-12 Airplane Build, Section 27 Rudder Pedals & Brake System (part 2)

Reference: page 27-03; 3.5 hours

I'm just starting to have fun with the RV-12 rudder pedals. Van's Aircraft has done a nice job designing a simple light setup for their ELSA aircraft.

Step 1: There are 1/8 inch holes in both sides of the Brake Pedals. Match-Drill #30 the hole in the one side of both brake pedals into the underlying Brake pedal Torque Tubes. Cleco, then match-drill the hole in the other side.

Step 2: Drill #12 all the way through the holes in both sides of the Brake Pedals and the Brake Pedal Torque Tubes, then final drill 1/4 all the way through.

Step 3: Remove the Brake Pedals and Brake Pedal Torque Tubes. Mark the parts to be reinstalled in the same locations.

Step 4: Repeat the same process for match-drilling and final drilling the Brake Pedals and Brake Torque Tubes for the other end of the WD-1206 Rudder Pedal assembly. The parts are assembled as shown in figure 2 on page 27-03 of the RV-12 aircraft plans.

Step 5: Grease the Brake Pedal Torque Tubes then slide them into the Rudder Pedals.

Builder's note: I used Aeroshell #5 grease on the torque tubes.

Step 6: Secure the Brake Pedals and Pedal Blocks to the Torque Tubes using the hardware called out in figure 3 on page 27-03 of Van's Aircraft plans. File away any portion of the pedal block that interfere with the welds on the brake pedals or Rudder pedals.

Builder's note: I had to use the low end of the torque range for the bolts holding the pedal blocks part F-1290. Otherwise the block ends would start to pull away from the rudder pedal tube if too much compression is applied with the bolt.

Step 7: Attach the master cylinders to the Rudder Pedals and the Torque tubes using the hardware called out in figure 3. of the RV-12 aircraft plans.

Step 8: Remove the lower halves of the Rudder Pedal Blocks and slide the whole Rudder Pedal Assembly into position in the fuselage as shown in figure 4 of Van's Aircraft plans page 27-03.

Builder's note: I left the rudder pedals assembled as shown until I was ready to slip it into place at that time I removed the nuts and washer onto of the UMHW blocks slide it into place and installed the bolts. It all went very smoothly this way.

Step 9: Secure the Rudder Pedal Assembly to the F-1201B Firewall Shelf and the three F-1257 Rudder Pedal Support Channels using the hardware called out in figure 4 on page 27-03.

This completes page 27-03 of the RV-12 plans. Next time I will start on fabricating the brake lines for the RV-12 aircraft.