http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/ en-us Gallery 2 RSS Module, version 1.1.8 Sun, 10 May 2026 16:46:08 +0000 120 http://www.europaowners.org/gallery2/d/387793-8/FRONTCABLEATTACHMENT.jpg http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/ http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00862.JPG.html http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00862.JPG.html
I used 1/4" piloted 100 degree countersink from Aircraft Spruce for the front cable mounting holes.
I used a 5/16" piloted 82 degree countersink from McMaster for the master cylinder mounting holes. I thought the insert for the master cylinder was an aluminium insert, but it turned out it's solid fiberglass (perhaps something like G-10?).
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I need to make a cut-out for the master cylinder lever and fill all that is not level because of my lay-up.

Y13-12-30]]> rparigoris photo Tue, 31 Dec 2013 05:16:15 +0000 http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00861.JPG.html http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00861.JPG.html
Forward cable mounting holes drilled using my drill guides.
Worked well.
The guides popped right off with a Irwin channel lock pair of pliers.
I need to cut down the length of the flat head master cylinder mounting screws.

Y13-12-30]]> rparigoris photo Tue, 31 Dec 2013 04:47:42 +0000 http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00860.JPG.html http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00860.JPG.html
Lay-up complete.

Y13-12-30]]> rparigoris photo Tue, 31 Dec 2013 04:43:46 +0000 http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00858.JPG.html http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00858.JPG.html
Fit is now good enough, will work on tapering the front side to match the tunnel (with 2 BID behind it).

Y13-12-27

Update Y13-12-29:
Sculpted the front and back side to fit tunnel pretty nicely, then scuff sanded with 80 grit, washed with very hot water and Palmolive, wet out with Aeropoxy, then filled holes with a dry mix of Aeropoxy/Q-cel.
Didn't add very much weight at all. Q-Cel is a lot harder to sand compared with Expancel, but think it's probably a bit stronger.
After cure of Q-Cel on insert (and sanding things flat), floxed corners of tunnel, and 2 BID +2.25" all around, then floxed in place the insert (~ 1/16" all over) and after squeegeeing off excess flox, 2 BID +2.00" all around and over the insert, then Peel Plied.]]> rparigoris photo Mon, 30 Dec 2013 02:37:08 +0000 http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00857.JPG.html http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00857.JPG.html
I spent some time at the 6" wide belt sander (keeping things cool with a container of water close by) carving the back to fit the shape of the tunnel.

Y13-12-27]]> rparigoris photo Fri, 27 Dec 2013 16:58:18 +0000 http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00856.JPG.html http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00856.JPG.html
Lightened up a bit.

Y13-12-27]]> rparigoris photo Fri, 27 Dec 2013 16:56:33 +0000 http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00855.JPG.html http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00855.JPG.html
The black dots on the clear tape template are the front flap cable mount locations.

Y13-12-27]]> rparigoris photo Fri, 27 Dec 2013 16:55:49 +0000 http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00854.JPG.html http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00854.JPG.html
Layout of lightening holes.

Y13-12-27]]> rparigoris photo Fri, 27 Dec 2013 16:54:28 +0000 http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00853.JPG.html http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00853.JPG.html
3/16" thick 6061 being used for front Hardpoint. Even though the tan foam is ~ 1/8" thick, I'm going to use countersunk screws, so after carving things to shape, should have at least 1/8" of thickness. The area of tunnel this will be living in is not absolute flat, thus requiring carving to shape.

Y13-12-27]]> rparigoris photo Fri, 27 Dec 2013 16:52:38 +0000 http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00852.JPG.html http://www.europaowners.org/gallery2/v/Begin-06-2003/Landing+gear/FLAPDRIVE/FRONTCABLEATTACHMENT/DSC00852.JPG.html
Temporary mounting screws for the drill bushings while the JB cures.

Y13-12-27]]> rparigoris photo Fri, 27 Dec 2013 16:49:54 +0000