Category: Rudder Pedals

April 8, 2015 – Yesterday I took the brake pedals to get powder coated. Then I made the center support for the rudder pedals.

I trimmed the bracket to clear the firewall recess, and marked out the holes to attach the bracket to the firewall.

With the rudder pedals in place, I put the bracket where it belongs, and drilled. Since the rudder pedals are ground-adjustable fore and aft, I had to drill multiple sets of holes. I only drilled two sets of holes, where I had drilled three sets on the outboard ends. I decided that the aft-most setting would most likely never be used.

Here’s the bracket seen from inside and outside:

Here’s the drilled bracket:

Then I shortened the bracket, removing the unused portion, and I cut a lightening hole.

I test fit everything one more time before taking it all out to start on the floor stiffeners.

Time: 2:25

April 3, 2015 – I needed to figure out where to position the brake pedals so they’d be out of the way during normal rudder use. I decided to place them a bit forward of center.

I clamped the rudder pedal “hangars” together so they were in line all the way across.

I then clamped angles to the brake pedals so they were in the same parallel position. The angle rested against the back side of the right rudder pedal, since the pedals are offset from each other. This gave a forward angle of a few degrees from vertical.

With both pedals tied together in the same relative position, I could drill the holes to attach the brake master cylinders. I used the trick so many others have done: placing a drill bit through the mount hole of the master cylinders and marking a line on the tab of the pedals.

I marked the center point on that line and drilled using a #30 bit. Then I placed a reamer through the master cylinder mount holes and took the holes up to size.

I placed the rudder pedals into place in the fuselage to check the fit. Got a little mixed up between left and right, and the side blocks are drilled slightly at an angle to allow for fuselage taper. You can’t really see it but the blocks didn’t fit well. I figured out their correct orientation and all is well.

I want to powder coat the pedals for wear resistance. I assembled the four pedals, and am waiting to get them  out for powder coating.

Time: 3:20

April 1, 2015 – I am putting brake pedals on both sides, so the airplane can be fully operated from either seat. By way of explanation for some who aren’t as familiar with the RV setup, the rudder pedals are made of welded tubing and is installed for both seats. The brake pedals are attached to the rudder pedals. The stock setup is to only have brake pedals on the left side for the pilot. This can prevent unwanted brake activation from the passenger. Some builders just have the brake pedals on the left side, others put brake pedals on both sides. So the bulk of the work you see here in the next few posts is for the brake pedals.

I started the pedals by cutting 8 angles 4″ long. These attach to the sides of each brake pedal.

Each pedal also has a bracket for attaching the brake master cylinders. These all get drilled to the pedals. It’s easy to forget that left and right pedals have to be made. They are mirror images of each other.

I also countersunk the pieces as appropriate.

Here’s the pedals clecoed and ready for later assembly (front and rear views).

The rudder pedal tubes are supported at the airplane structure by hard plastic wear blocks. These have to be drilled to the airplane. I drilled these blocks like I did the flap blocks. Many people use a drill press to make sure the holes are straight. I do it by hand, and the holes are straight if you are careful.

I marked the hole locations on the top and bottom of the blocks.

Using a #30 drill bit, I drill halfway through the block, then turn the block over and do the same thing. The theory is that the holes will meet in the middle.

I used a reamer to take the holes to final size. The reamer will clean up any minor inaccuracies if the starter holes didn’t perfectly line up.

I also drilled the center support block the same way. I use a silver Sharpie to mark these black plastic blocks.

The side blocks are to be placed no closer than 3″ from the aft face of the firewall. I marked that point on the side angle in the fuselage, then used a long #10 drill to back drill the angle.

You are allowed to drill additional holes to allow for fore and aft adjustment of the pedals. I marked mine 1 1/16″ aft of the original forward-most location, and then an additional 1 1/16″ aft of that. So I have six holes for future pedal fore and aft adjustment.

I started assembly of the pedals out on the table. I have to install the brake master cylinders. Since the pedals are offset from each other, I had to stand back and think about how to locate and position the pedals. More to come on that…

Time: 5:00