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Brake systeem

The construction of your own cockpit.

It’s time again to write a sequel.  The last European Contest has proved that an enormous interest for our cockpit constructors exists in the club and also abroad (due to the website of the club).  This means a great support for me and gives a special boost to end the project well.   I can’t refrain from thanking you all and keep you up to date of the progress that I’m making. 


The brake system:

In my last article I ended the construction of the pedals.  An important part of the pedals is the brake system.

techrem1 techrem2









How does it work ?

By pushing (pressing) the upside of the left or the right pedal the brake system starts working.  Moreover the system works simultaneously for pilot and co-pilot, no matter what the position of the pedals is.  Making it more complicated does the handbrake.  Pressing together both brakes you can put the handbrake on and off.

It wouldn’t have been an easy task for McDonald Douglas to have these things working in a very small space.  Happy I was I needn’t to invent this, because I have the necessary detailed technical drawings (fig. 1 & 2) at my disposal.  But even possessing these drawings it wasn’t an easy task.  
I don’t own a lathe, easy to make the pieces fit precisely one in each other; so, I had to look for a metal bar that fitted exactly in a tube, which, at its turn, had to fit in a bit bigger one.  Some exploring and measuring did the job well.

remsys1 remsys2 remsys3 remsys4





Why all these tubes and bars ?
To link the left pedal of the pilot to the left pedal of the co-pilot, they found the following: one links the pedal at the left side by a rail to the central bar.   In the middle of it, this bar is connected by a union to a tube that goes to the right side.  By means of a rail, this tube is connected to the left pedal of the co-pilot.  For the right pedal it is just the contrary.  This simple explanation shows how the pedals at both sides work synchronously. 







To have all this working – what ever the position of the pedals may be – you need some conductors that always keep the rails, coming from the pedals, in the correct position.  If the rail, that is connected to the bar or tube, would be too upright compared to the rail of the pedals, it wouldn’t work at all.  You always need a specific angle.  Moreover the conductors also control the rails not to move too much upwards or downwards.  This will give you a clear view when you study drawing n° 1 carefully.  You have surely seen that the size of the left conductor is different from the one on the right side.  Everything will become obvious once we add the handbrake.

The handbrake consists of two tubes fitting in each other.  To the right side it is connected with a rail, handle included, that goes to the pedestal in order to have the handbrake operating; at the other side it is connected with the left-side conductors.  The conductors at the left side have been made of flat sheets in which a curved upside down “L” has been worked out.
By pressing both pedals and pulling the handle of the handbrake , you can push the two conductors to the front and the pedals keep their brake-position.  To clear them you again press the pedals and push the handle to the front.  The conductors move to the backside  and the pedals take their normal position. 

pedal2 pedal3 pedal4






To have the pedals always going back to their normal position I linked two springs to each tube.  These springs make it possible to feel a certain resistance when you press the brakes, preventing you from unnecessary braking.  The lather could have catastrophic consequences when taking off. 
In any case it is more simple now to turn with my DC3, having the possibility to brake by sections and to turn my pedals with the brake system.
Linking it to the computer is another story.

pedal5 pedal6






Now I’m constructing the steering column.  It is almost finished.  I’ll tell you more about it in one of the next Airmails. 
If you have any questions, suggestions or information about my project, contact me on my e-mail address (see contactinfo)



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© Verley Jan 2007-2017 original text from 2002 translation Joan Pacquets