Canadian Flag Blowing In The Wind Ron Leclerc Zenith CH701 Construction Log


Zenair CH701 STOL Aircraft...
CH701 STOL

Winnipeg

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701 Rudder: 1 | 2 |    Next...
 

Rudder Parts Forming Blocks!

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May 15, 2007
Stock Rudder Parts Forming Blocks...

 

Stock Rudder Parts!

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June 5, 2007
Lower Rudder Hinge Assembly
7F4-2 Lower Rudder Hinge 0.063
7R2-3 Rudder Horn 0.090
7F4-4 Tie Down Ring 0.040

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June 15, 2007
Rudder parts formed and ready for building the rudder skeleton. Waiting for the Spar, where the "****" is it...

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June 16, 2007
7R2-4 Upper Rudder Hinge Angle 2 Required - 3/4 x 3/4 - 0.125...

 

New 701 Tail Feathers!

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July 25, 2014
New Vertical Stabilizer and Rudder - similar to the 750 CruZer

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August 11, 2014
Frame Skeleton Assembly for new Vertical Stabilizer.

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August 11, 2014
New 701 Rudder Horn Modified Drawing - 0.125" 6061 T6! Note the extra attachment points for Float Rudder...

 
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August 11, 2014
701 Modified Rudder Horn Pattern - New Rudder! Note the extra attachment points for Float Rudder...

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August 11, 2014
701 Modified Rudder Horn Drawing & Pattern - New Rudder! Note the extra attachment point for Float Rudder...

 

 
Rudder Cable Fairings!

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August 15, 2008
Rudder Cable Fairings... forming block. Two 80mm x 80mm 3/4" plywood blocks, hinge and 1/2" bolt. The two... 3/4" plywood blocks are clamped together and a 1/2" hole is drilled at a about an 8 ° angle to the vertical, hinge is attached and you are ready to go. A half an hours work... check out the construction on the tools page...

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August 15, 2008
Rudder Cable Fairings... 0.025 aluminum used instead of 0.016 design spec. Cut the aluminum blank 80mm x 80mm... form and then trim as needed...

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August 15, 2008
Rudder Cable Fairings... cut to shape with nylon fairlead attached ready to be installed on the fuselage...

 

Modified Rudder Brake Pedals!

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August 20, 2008
Modified Rudder Brake Pedal Pattern... NOTE: That a 5/32" relief hole must be drilled in the 0.090 aluminum at the point where the brake arm meets the pedal... before the arm is bent otherwise bending without this hole will cause the aluminum to crack at the bend point...

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August 20, 2008
Modified Rudder Brake Pedal... 0.090 aluminum used. Cut the aluminum blank, drill the 5/32" relief hole, then form the brake arm and drill the 1/2" holes on 3/4" centers... then it's ready to be riveted onto the rudder pedal with a piece of 4" x 1+1/2" hinge and A5 rivets...

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August 20, 2008
Modified Rudder Brake Pedal... pilot side ready for installation... The co-pilot side can be done also...but the brake arm is located on the opposite side of the pedal...

 
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August 20, 2008
Modified Rudder Brake Pedal... Co-pilot side ready for installation...

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August 20, 2008
Modified Rudder Brake Pedals... Pilot side and Co-pilot side brake pedals... 0.090 aluminum

 

Rudder Position Light Construction Assembly!

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November 28, 2008
A Keenes Mustard Jar 2" O.D. is just the right size to fit inside of the 2" ID PVC pipe and also has a metal cap... I used whatever material I had to make the parts from, but the Mustard Jar with a metal cap was just perfect. Of course I had to find someplace to put the mustard... but that was no problem...

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November 28, 2008
Mock up of the trailing edge of the rudder. The piece of PVC pipe is about 6.5" long... with the start of the "V" about 2" back. This part will be adjusted to allow for the required light pattern needed. The "V" shape is cut with bandsaw from a pattern that matches the rudder trailing edge(used a rib from the rudder). A piece of foam is glued to the PVC pipe and formed to a nice finished shape...

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November 28, 2008
Mounting ring of 2" diameter... 1/8" aluminum glued with epoxy to the inside of the PVC... located just back of the "V". This ring is where the metal cap, #93 bulb light fixture(from auto shop) and 1/8" spacers are mounted onto with self-tapping #10 screws. Also a ground wire must be soldered to the fixture... to provide a ground connection for the light to work...

 
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November 28, 2008
Position light parts ready for assembly, cost is about $5. A hole is cut in the metal jar cap and will be fastened to this ring along with the bulb fixture and spacers with self-tapping #10 screws after it is glued in place. The jar is then turned onto the metal cap nice and snug...

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November 28, 2008
Position light assembled... ready to be mounted onto the PVC pipe... notice that the 2" ring must be expoxied into the PVC pipe and a ground wire soldered to the bulb fixture...

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November 28, 2008
Here is the position light... ready to be finished. The inside of the pipe had to be shaved down with the Dremel to allow for just a bit more room for the jar. The jar was 2" in diameter and had a bit of a tight fit, the same as the PVC pipe... thus the use of the Dremel. The biggest cost in building this position light will be the 3 layers of 6 oz fiberglass and 1 oz of fiberglass as the final top layer...

 

 
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