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Cabin Floor and Rudder Pedals

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Michael Valentine

Joined: 09 Jan 2006
Posts: 108

Posted: Sat May 12, 2007 7:23 pm Post subject: Cabin Floor and Rudder Pedals

Listers - I am done with my firewall (thanks for the help) and on to the cabin floor.  Unfortunately, some guy on his first day at the factory must have made the floor (6B10-1) because it is pretty shoddy.  The bends of the "wings" are a couple mm off, leading to some problems with the centerline and edges in relation to the holes.  But, so far I have been able to make everything work.  Until now. 



I just drilled the central pedal bearing (6b9-4) holes.  The factory pilot holes were so far off that I had to squeeze one pilot hole way over to the side of the center bearing hole and the other pilot hole way over to the other side of the other hole (the aft hole) just to get the pilot holes inside the 3/16 holes.  It almost worked.  I am going to have to talk with Zenith about drilling one of the holes out to a AN4 instead of an AN3.   



But, the real problem is that despite trying to line everything up and make the holes fit, the bearing is at a tiny bit of an angle.  Thus, when I put the rudder pedals in the bearing, the pilot side pedals aim slightly aft.  When I go to slide the lateral pedal bearing (6B9-5) over the end of the pedal tube, it won't fit.  The pedal comes too close to the edge of the channel so the channel interferes with the lateral bearing. (I don't think the other side really matters because it is just sitting in the open part of the channel, but I will ask.) 



As I am writing this at almost midnight on Saturday, I obviously have not contacted the factory yet.  But, do you all think it would work with the right tools/shop/help to slightly bend the rudder pedal tube.  If I put a slight bend it, I could inch it away from the channel edge.  (Even as I type this, I realize that such a route might cause a bit of trouble if the pedal is not high enough off the floor so that the bend rubbed as the pedals rolled in and out, but I could probably figure out before hand if that will be a problem.) 



Anyway, if anyone wants to take the time to visualize this mess and pass on a suggestion, I would appreciate it.  With all the holes drilled in every piece, my only other option is probably to get all new parts for the cabin floor.  (How annoyed should I be at Zenith if this happens?  Would you buy or request new parts?) 



Thanks, Michael in NH

601XL

  [quote][b]

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craig(at)craigandjean.com
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Posted: Sat May 12, 2007 11:02 pm Post subject: Cabin Floor and Rudder Pedals

I may not be clear on  what the problem is but would making a custom bearing remove the need to replace  any metal?

  

 --  Craig

   [quote][b]

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p.mulwitz(at)worldnet.att
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Posted: Sun May 13, 2007 3:10 am Post subject: Cabin Floor and Rudder Pedals

Hi Michael,



 I feel your pain.  I am just now taking my cabin floor apart for deburring, painting, and riveting.



 I don't think I would bend the steel weldments to make it all fit together.  Firstly, they are very difficult to bend.  Secondly, I don't think they would ride correctly in the bearings if they were bent.



 I would probably insist ZAC send me a properly made cabin floor part.  If I wasn't willing to wait, I would drill new holes where they are actually needed and add reinforcements when the proper edge distances were not met.  The reinforcements might be small washers of the same weight as the damaged part riveted on the far side or they might be larger pieces of similar material.



 I wish you luck,



 Paul

 XL fuselage

 do not archive



 At 08:22 PM 5/12/2007, you wrote:

 [quote]Listers - I am done with my firewall (thanks for the help) and on to the cabin floor.  Unfortunately, some guy on his first day at the factory must have made the floor (6B10-1) because it is pretty shoddy.  The bends of the "wings" are a couple mm off, leading to some problems with the centerline and edges in relation to the holes.  But, so far I have been able to make everything work.  Until now. 

  	  Quote: 	
		  

[/b] 	
[b]

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Michael Valentine

Joined: 09 Jan 2006
Posts: 108

Posted: Sun May 13, 2007 6:34 am Post subject: Cabin Floor and Rudder Pedals

Thanks listers - a couple people have made this bright suggestion.  Can someone point me in the direction of where I can get the bearing material?  (If you missed the earlier email we are talking about the rudder pedal bearings.) 



Thanks, Michael



On 5/13/07, Craig Payne <craig(at)craigandjean.com (craig(at)craigandjean.com)> wrote:[quote]      I may not be clear on  what the problem is but would making a custom bearing remove the need to replace  any metal?

  

 --  Craig



[b]

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craig(at)craigandjean.com
Guest

Posted: Sun May 13, 2007 9:42 am Post subject: Cabin Floor and Rudder Pedals

The plans list the  material as "Nylon66" (on page 6B9). Spruce sells "Nylon"  but I wouldn't  assume it is the same (superficially green vs.  white):

  

 http://www.aircraftspruce.com/catalog/mepages/nylon.php

  

 The scratch builders  should be able to say where they obtained  theirs.

  

 Here are the physical  properties of "66":

  

 http://www.3d-cam.com/materials/nylon_66_6.asp

  

 This page seems to  indicate sub-types within 66:

  

 http://www.ashleypoly.com/nylon_guide.htm

  

 So the safest and  simplest source is Zenith. You can order most parts "undrilled" but you may have  to specifically request a block of the raw material. Given the sequence of  events I bet you could persuade them to give it to you free. But I think you  should find a machinist to actually make your custom  block.

  

 Do you have any  pictures of the problem?

  

 --  Craig

   [quote][b]

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planecrazydld(at)yahoo.co
Guest

Posted: Sun May 13, 2007 10:53 am Post subject: Cabin Floor and Rudder Pedals

www.mcmaster.com

www.usplastics.com



Craig Payne <craig(at)craigandjean.com> wrote:[quote]     The plans list the  material as "Nylon66" (on page 6B9). Spruce sells "Nylon"  but I wouldn't  assume it is the same (superficially green vs.  white):

  

 http://www.aircraftspruce.com/catalog/mepages/nylon.php

  

 The scratch builders  should be able to say where they obtained  theirs.

  

 Here are the physical  properties of "66":

  

 http://www.3d-cam.com/materials/nylon_66_6.asp

  

 This page seems to  indicate sub-types within 66:

  

 http://www.ashleypoly.com/nylon_guide.htm

  

 So the safest and  simplest source  is Zenith. You can order most parts "undrilled" but you may have  to specifically request a block of the raw material. Given the sequence of  events I bet you could persuade them to give it to you free. But I think you  should find a machinist to actually make your custom  block.

  

 Do you have any  pictures of the problem?

  

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