PHASE 2 AXLE STRUT ASSEMBLY |
PRINTS :
G2-1 Axle Strut
G2-2 BracketsG2-3 Saddle Fittings This is explained in phase #3
G2-4 Assembly
HARDWARE :
4 ---- AN4-21A bolt
8 --- AN460-416 washer
1 --- AN365-428 nylon lock nut
MATERIALS :
2 ----- 1-1/4" x 8" ---- 6061-T6 -- Aluminum round stock --- for the axles if you are going to use them.
2 ----- 1-1/4" x 1" x 32" ---6061-T6 -- Aluminum tubing -- for the axle struts
1 ------1-1/4" x 12" --- 6061-T6 Aluminum square stock -- for the saddle brackets shown in Phase #3
OTHER MATERIALS :
8 --- U Small brackets --- order from one of the following places : L.E.A.F., Starbee's gyro, aircraft spruce or Bear Pearkins
2 --- U Big brackets --- order from one of the following places : L.E.A.F., Starbee's gyro, aircraft spruce or Bear Pearkins
1 --- Black max brake system ---
FABRICATION :
G2-1 Axle Strut :
I cut the axel struts 32" long. This way it would save on weight as well as the width of the trailer I was going to need to make to haul it down the road.
We did not use the same plans as listed below, I did not like the idea of placing bent metal on the aircraft and it would lower the keel to the ground. Also it would be hard to get this bend in the same place on both struts.
* G2-2 Brackets :
I bought the U brackets from Aircraft spruce $4.75 ea.
G2-3 Saddle Fittings
I made them and it is explained in phase #3
G2-4 Assembly
Since we wanted to install a brake system to the aircraft we had to do some modification of our own. See Phase #18 The brake system. It shows the part that we made to install inside of the axle struts. other than that this phase was to the plans of the Gyrobee.
This picture was the finial part and what it looked like.
"GYROBEE PLANS"
FABRICATION :
Since we are going to change a few things here the plans are going to followed some what.
The following steps were used to assemble the right axle strut as shown in print G2-5, then repeat for the left strut : At the outboard end of the strut (the end with two holes), insert a KB-2 axle (comes with the KB-2 wheel set) so that the shoulder extends 0.25 inch beyond the tube end. Secure the axle and strut and match-drill through the axle at the outboard 1/4 inch hole. This job should be done slowly and carefully with oil to assure a clean drill cut. Temporarily pin the axle in place with a 1/4 inch bolt, rotate the strut 90 degrees and match-drill the second 1/4 inch hole at the outboard end of the strut.
Place saddle fittings on either side of the outboard axle hole and secure a small bracket with the indicated hardware. Note that the outboard bracket should face "up" Repeat with the inboard saddle fittings and another small bracket, with the bracket facing "forward".
G2-1 Axle Strut. The struts had to be bent as indicated to improve ground clearance with the KB-2 main wheels. This is a tough job given the 1/8 inch wall
thickness of the axle strut tubing. We accomplished the bend by anchoring one end of the strut against a wall and used a truck wheel as a bending mandrel using
a come-along to provide the bending force. It is important that both struts have the same final offset, even if the absolute value is a little off the 3.75 inches shown on the print.
G2-2 Brackets. These can be fabricated from stainless sheet stock or the indicated brackets can be ordered from LEAF.
G2-3 Saddle Fittings. We farmed these parts out to a local machine shop.