Construction of mostly metal parts used for flight controls.
Album by John Cronin. Photos by John Cronin. 1 - 96 of 96 Total. 1796 Visits.
Cutting bushings and collars for the torque tube.
Still have to clean these up.
I've made bushings and collars for the torque tube, and blanks for the safety strap, rudder bar mount and safety belt brackets.
I've cut the aileron control horn out and now cutting the hole for the torque tube.
Knocking off the rough edge.
Fits well.
Ready to cut the second horn.
I made a guide so the hole is cut to match the other horn.
Cleaning it out.
Good fit and matches other horn.
Starting to bend the rudder pedal attachment fittings. I thought I should bend it before drilling the holes as I'm not sure if the holes would be distorted (by the bending).
I marked on tape where I want the AN3 bolt heads to be.
About to drill the first hole; it's 3/16" (using a step bit).
Done.
Now working on the pulley brackets. I'm transferring the hole.
I use a washer to guide my drill bit.
I use a centering drill bit.
Black clamp holds the wood. The other bracket holds the work.
I lubricate parts when drilling metal. I use an eye dropper.
About to use a "D" drill bit. The clamps are not moved. The entire table swings out to change bits. The washer guide has been removed.
The hole has been drilled.
Done. I normally finish with a reamer, but the AN4 fit fine. Not sure yet if this is the actual size AN4 I'll use.
About to run a "D" bit into tubing which will be the bearings for the control sticks (to torque tube).
Now about to ream it.
Shaping the tabs that connect control sticks to the torque tube.
About to cut two control sticks from that bar. They will be a bit long for now.
About to drill the first of two holes into the torque tube for the bushing where the control sticks connect.
Going to use this for bending metal which will be used to squish tube bottoms.
Like this.
Getting ready to squeeze the bottom of rudder pedal. The 1/16" wood is to keep it square and somewhat centered on the metal backing.
In place in my heavy duty vise.
One side done. Now for the other. I used a BernzOmatic MAP-Pro Hand Torch. Doesn't quite get it red, but I'm able to squeeze the tube.
Drilling a hole into the aileron control horn. The wood is to level it since the metal is curving.
All welding is being done by a professional.
I drilled a hole into the forward and aft bushings so I could drop some oil in to keep them lubricated.
Used this small round file to get rid of any burrs.
I cut a slot into the pilot control stick for the lug (for elevator control cable).
Cutting small lugs which will go into each control stick. A rod will connect each thus joining both the forward and pilot control sticks.
Making marks for the drill location in the rudder pedals.
Using a #14 drill bit.
Then used a 3/16" reamer. Perfect fit.
All holes and brackets are numbered since each is unique.
Drilled cotter pin holes in the lugs (for joining control sticks).
About to drill a hole for the lug (in the pilot control stick).
The pulley info.
About to squish the ends of the tube that connects both control sticks. The back piece of metal needs to be as far to the right as possible. I forgot at the moment.
Drilling a hole for the lug.
All together.
This is when a shop was welding it.
I rounded corners of the six pilot seat belt brackets and control sticks connecting tube.
Pilot seat-belt brackets.
Working on the pilot rudder bar. You can see the ends have been squished and drilled.
Now centering and getting lined up for the center mount bushing.
That came out OK. Will have the shop weld it.
Bought a metal bender from Harbor Freight. About to make the rudder post.
About to bend the middle (top).
The other side. I already bent one foot.
That was scary, but worked out.
Drilling the rudder post.
A foam board will help shape the metal support bracket.
Started drilling holes to mount the torque tube.
This one was tricky. Glad I had this special tool.
Needed to raise torque bar; the bar connecting both control sticks is hitting rudder bar post. I made a new change though and NOT doing this. read ahead.
Making the elevator and rudder horns.
All cut and trimmed to size.
Bending the trailing edges.
I'm using the shortest bolt in the rudder bar that'll work. Now, I don't need to raise the torque bar.
