Rudder Pedals - Part 4

Pilot and Co-pilot rudder pedals are connected using the stainless steel connecting rod's supplied with the kit fitted with M6 threaded rod ends at both ends.

This assembly was used to position the rear pedals - on this aircraft 10 - 12 mm of thread was left projecting from the end of the connecting rod. Both rods were adjusted to the same length and installed to set the position of the rear pedals. 

The pedals have to be fitted before the rod can be be installed finally.

Connecting Rod Installation

With both pedals installed the final center distance can be determined. The factory supplied M6 nylock nuts to lock the rods end but this builder favored a traditional method of a lock [half] nut. 

One issue that had to be considered is maintenance with access to the front attachment only through removable hatch's in the panel cover.  Examination showed that with the limited clearances use of Loctite would create great difficulty in the future. Even hex headed bolts would be a tough job and using cap head screws would prove impossible.

The method described required silver brazing the factory area washer onto the underside of the bolt head with the bolt locked using wire secured to a suitable tab. 

Four [4]  tab's were fabricated from 0.015'' annealed 304 S/S sheet from the firewall fabrication. 

Rod End Mounting Components

To ensure that that both assembly's are at the same centers a simple jig was manufactured by drilling 1/4'' holes into the edge of the work bench at the finished centers. To keep the rod ends on the same plane while tightening the nuts the rod ends are locked using two over size washers, M6 bolt and a clamp. The washers and clamp will lock both rod ends parallel to the table allowing the locking nut to be fully torqued while holding the tab in its correct location for ease of assembly.

Torquing lock-nut against tab and spring washer
Tang of file stops the tab from rotating

Fanged Bolt
Bolt are plain shank in rod end

The tab and lock-nut are secured against a M6 spring  washer at assembly. 

Assembly required the pilot pedals to be bolted first then the the co-pilots using the flanged bolts. Before installation four [4] 1/16'' holes are drilled in the flange of the bolt washer for the lock wire attachment. 

The bolts were inserted and tightened and operation checked.

Comment

The components are painted red for inspection and to allow passengers to be told "If its red do not impede it operation" as it a little tougher to monitor people in a tandem.