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Zenith CruZer & Sonex Logs
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Date: 6-20-2010
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Number of Hours: 3.70
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Manual Reference:
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Brief Description: Rig Main Gear Axles
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New area today; main landing gear / axles / brakes.
Raised the fuselage after getting a new HD sawhorse. Additional height was required in order to allow insertion of main gear legs from underneath the fuselage.
Re-installed main legs into motor mount; just held in place with AN4 bolt w/o nut.
Axles came pre-drilled in end; had to tap for 10-32 screw which will be used to attach the gear fairings. Additionally, other builders had noted that the brake assembly mounting "ear" on the back of the axle (visible on the upper axle in pic 3 below) was a bit too close to the weld fillet, so I used a dremel tool and a carbide bit to provide the desired clearance for the AN3 bolt head. Also drilled a 1/8" pilot hole in the side of the axle assemblies as per plans.
Before the axles can be mounted to the gear legs, the toe-in must be set. To do this, one obtains a 6' length of bar stock or other rigid material. I used an old section of 2x2" railing material that I had out in the barn. To set the toe-in, a spacer ring is slipped over the axle (visible in 2nd pic below), which forces the outer end of the axle to toe-in the desired amount. Very simple, yet elegant. Like other builders, I had to use spacer blocks because the railing material hit up against the axle housing. I used bungee cords to hold the axle tight to the railing. Used a 1/8" drill to just mark the location of the axle assembly hole in relation to the gear leg using the previously drilled pilot hole in the axle.
Took it all apart, and set up the gear legs to be drilled. Went straight with a 1/4" hole; no pilot. Clamped into the V-block on my drill press and used lots of oil and slow steady pressure to cut two holes. Up-drilled the pilot holes in the axles to 1/4", then slipped the axles over the gear legs and drilled thru the axle and gear leg out the back side of the axle. Results shown in pic 3 below.
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Fuselage raised to new heights
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Spacers in Place, Setting .07" Toe-In
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Gear Legs Drilled; Axles in Place (not correct HW)
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