Having nice wooden flight sticks, my wife also wanted an appropriate improved (better looking) flap handle. With the support of a friend in “wood business” I fabricated the wooden flap handle in the picture below. Much better looking, but only experimental builders can afford such a time consuming part 🙂Continue Reading... No Comments.
After the brakes were filled with fluid, I tested them. I put pressure on it and checked every connection. No leak occured. The parking brake is working well. Even after several days there was still enough pressure in the system that we could not move the wheels.Continue Reading... No Comments.
Filling the brakes with hydraulic fluid was a job I often thought of. Having done this never before, some consideration was made how to perform it. In the end it was an very easy job. Take a simple oil can with a small tube, connect it to the bleeding inlet at the bottom and […]Continue Reading... No Comments.
The manual says to insert the pedal return springs into a hole at the side of the motor mount. I did this first, but was absolutely unhappy with this. Very hard to put the spring into this hole and if you need to vary the spring position you need a row of holes in […]Continue Reading... No Comments.
We installed a parking brake in the Rebel. There is a very good description available online from Roee Kalinsky (http://www.kalinskyconsulting.com/rvproj/parkingbrake.htm). I copied this design with some modifications.Continue Reading... No Comments.
I decided to go with 4 brake cylinders. A lot of alignment work to get the pedals totally aligned. Although prepared before I had to wait for this step until the engine mount are positioned.Continue Reading... No Comments.
These pictures show the simple mechanism Murphy uses to fix the flap positions. Just an AN4 bolt which fits into a hole. Just pull the handle towards the pilot and move it to the different positions. Simple, but I like it. I just drilled the hole for the neutral position here. Others for […]Continue Reading... Comments Off on Flap Handle Bolt
Some gussets to reinforce the connection of the flap rib.Continue Reading... Comments Off on Flap Rib Gussets
It took me some time to find out the best way to route the teleflex cable. I wanted to make sure that my head has enough clearance at the top. This turned out to best the best way.Continue Reading... Comments Off on Teleflex Cable Routing
Picture shows the teleflex retainer at the flap rib, self fabricated from 0.125 Aluminum. You can also see the flap handle with the AN4 bolt for fixing.Continue Reading... Comments Off on Teleflex Cable Retainer
The picture shows the flap handle design. I decided to go for a slightly modified standard flap handle . The handle has a modified “hockey stick” design, to keep it out of sight. The handle was then equipped with some wood for better handling. Maybe a rubber cover will be installed over it later.Continue Reading... Comments Off on Flap Handle Design
These fairings are also from 0.020 and protect the exit of the elevator P/P tubes.Continue Reading... Comments Off on Elevator P/P Fairings
These fairings protect the rudder cable exit holes in the fuselage. I fabricated them from 0.020.Continue Reading... Comments Off on Rudder Cable Fairings
Elevator cables are installed. I used BB-128 (ACS) pulleys at the front.Continue Reading... Comments Off on Elevator Cables
With the posterboard model of the console we checked the ergonomics. A simple throttle quadrant model was installed as well, so the tests could start. We are very happy with the ergonomics. Everything is well in reach and gives a relaxed flight.Continue Reading... Comments Off on Center Console Ergonomics
We decided to build a center console for the Rebel. Thus we can install a throttle quadrant for the motor. The pictures show the model, built from paperboard.Continue Reading... Comments Off on Modelling Center Console
I decided to install pulleys at the front and back of the forward fuselage. The angle of the cable is changed by more than 3 degrees, so I prefer a pulley instead of the cable guides as written in the manual. I used 1 1/2″ pulleys from ACS (05-29725), a cheap solution and much […]Continue Reading... Comments Off on Rudder Pulley
The hanger is finally fixed. The tubes will be installed later, just before the wings are installed. Other than the instructions in the manual I fixed the hanger with AN3-5A bolts instead of RV-1613 rivets. This has the advantage to be able to dismount, but the main reason is shear load on the hanger. […]Continue Reading... Comments Off on Hanger Finally Fixed
The space between the tube (CC-50 to the mixer) was not enough. When pulling the mixer arm in the highest possible position, the tube touched the bell crank brace. To overcome this I cut (or better filed) a small cutout into the bell crank brace.Continue Reading... Comments Off on Bell Crank Brace Cutout
I didn’t like the suggested method in the manual how to connect the tube coming from the control column to the bell crank. The manual suggested to leave off the jam nut. That would mean all the movement in the tube (originating from moving the control column forth and back) had to be covered […]Continue Reading... Comments Off on Bell Crank P/P connection
This is a detailed view of the connection of the two control sticks. This looks very easy but it is a very tedious job to put the spacers inside the column. This job took a lot of time and nerves.Continue Reading... Comments Off on Inside Control Column
To make sure I do not have interference with the rudder cables, I finally painted and installed the aileron controls. One detail of this are the very simple but effective aileron stops in the base of the control stick.Continue Reading... Comments Off on Aileron Stop
Finding the best way through the fuselage for the rudder cables is a time consuming job. Lots of climbing in and out into the fuselage. I found this installation keeps the rudder cable rather straight.Continue Reading... Comments Off on Installing Rudder Cables
To make sure the P/P tubes are not interchanged, I color coded the mixer, th P/P tubes and the control horns. Thus you must be really dreaming if you misinstall these. I hope my FAA supervisor is happy with that. Isn’t that a nice red color !?Continue Reading... Comments Off on Color Coding Push Pull Tubes
Mixer mounted on the mixer arm. I decided to mount the mixer after the teleflex cable moun (as stated in the new version of the manual). It gives more clearance in the doors, that means the P-P tubes only slightly interfere with the door opening. There was an error in the manual concerning the holes […]Continue Reading... Comments Off on Mixer Detail
Detailed picture of the torque tube with push-pull tubes connected. I managed to temporarily install all this without removing the wings. Final installation will need wings removed.Continue Reading... Comments Off on Torque tube detail
The Push-Pull tubes have been constructed today. As mentioned by other builders on the list the length (tube only) is 26 1/2 and 26 3/4 for my rebel. All the tubes and the mixer are temporarily mounted, to be corrosion protected from inside before riveting.Continue Reading... Comments Off on Push Pull Tubes constructed
Today I partially mounted the torque tube, this is more time consuming than estimated.Working over head leaning backwards is hard, espacially when the temperatures are more than 35 degree Celsius in the workshop. Instead of using rivets for the hanger, I will use AN3 bolts. This will prevent sheared rivets been reported by experienced builders. […]Continue Reading... Comments Off on Torque Tube with hanger
I did the fuselage exit hole for the elevator push pull tubes this weekend. This was a tedious work. Filing and filing the hole until I get the 25 degrees upward and downward elevator travel. I did it step by step to have the hole as small as possible. In the end […]Continue Reading... No Comments.
This is the first (and probably only) time where normal rivets are used on the Rebel. It was really fun to hammer these down. But nevertheless I am happy all the rest of the rivets are blind rivets. Its a lot easier to pull them. Must be a nightmare doing an aircraft with […]Continue Reading... No Comments.