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ulbuilder |
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N349LE Ace
Posts: 302
Time Online: 8 days 20 hours 59 minutes
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I used a free on-line CAD program http://OnShape.com to create some drawings for the parts needed to add bicycle disk brakes to my 1030. Caution: My bird is not yet complete so no real world testing has been performed but so far they do work really well as a parking brake. Because of attachment size limitations I will need to attach the PDF drawings in additional posts, here are some pictures of the finished product EDIT: Updated drawing with reinforcement can be downloaded from here: https://ulbuilder.files.wordpress.com/2016/10/caliper-mount-drawing4.pdf
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ulbuilder |
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N349LE Ace
Posts: 302
Time Online: 8 days 20 hours 59 minutes
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Modified Axle mount drawing
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ulbuilder |
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N349LE Ace
Posts: 302
Time Online: 8 days 20 hours 59 minutes
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ulbuilder |
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N349LE Ace
Posts: 302
Time Online: 8 days 20 hours 59 minutes
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Arthur Withy |
October 11, 2016, 11:53pm |
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Happy 1500R owner - building a Jodel D18 Ace
Posts: 2,532
Time Online: 32 days 12 hours 14 minutes
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Ok thats great. Looking forward to your testing regards Arthur |
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Dick Rake |
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Home phone 602-999-3715/Mini-max with Hirth 2704 Ace
Posts: 755
Time Online: 40 days 13 hours 26 minutes
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Nice drawings and workmanship. Thanks for posting. Dick |
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beragoobruce |
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Built an Eros - now I'm flying it! Ace
Posts: 1,067
Time Online: 19 days 10 hours 59 minutes
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Looks great - bet they'll stop a Max pretty quick.
bruce |
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bigbrixx1 |
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Ace
Posts: 822
Time Online: 20 days 16 hours
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Keep this stuff coming! I am leaning very heavily in this direction! |
| V-max. Finished. Now in phase one flight |
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ulbuilder |
October 12, 2016, 10:14pm |
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N349LE Ace
Posts: 302
Time Online: 8 days 20 hours 59 minutes
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cliff |
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Flight Leader
Posts: 164
Time Online: 11 days 13 hours 8 minutes
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Very sanitary and pro looking work, they look fantastic and should perform just as well, it's inspiring to see innovations that are so well thought out and documented, outstanding fabrication skills! |
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radfordc |
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Ace
Posts: 1,836
Time Online: 18 days 1 hours
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Caution: My bird is not yet complete so no real world testing has been performed but so far they do work really well as a parking brake.
I built my brakes very similar to yours. When I first tried using them the mounts flexed so much that the calipers bent the rotor. |
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ulbuilder |
October 13, 2016, 11:38pm |
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N349LE Ace
Posts: 302
Time Online: 8 days 20 hours 59 minutes
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What did you do to prevent the flexing?
If I lock the brakes and try to turn the wheel there is a little flex in the caliper mount. I don't think it's enough to cause a problem but ideally there would be no flex at all.
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radfordc |
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Ace
Posts: 1,836
Time Online: 18 days 1 hours
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What did you do to prevent the flexing?
If I lock the brakes and try to turn the wheel there is a little flex in the caliper mount. I don't think it's enough to cause a problem but ideally there would be no flex at all.
When I first installed the brakes I saw the same thing your are...a little flexing when trying to turn the wheel by hand. The first time I used the brakes to stop the plane the mount flexed so much that the caliper bent the rotor. I added a steel cable restraint from the top of the mount back to an anchor point on the landing gear tubes (my plane is an Eindecker with a nice horizontal tube behind the wheels). The cable keeps the mount from moving forward. |
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radfordc |
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Ace
Posts: 1,836
Time Online: 18 days 1 hours
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ulbuilder |
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N349LE Ace
Posts: 302
Time Online: 8 days 20 hours 59 minutes
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I'm going to add the blue reinforcement pieces, this should be sufficient to prevent any flexing.
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ulbuilder |
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N349LE Ace
Posts: 302
Time Online: 8 days 20 hours 59 minutes
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Frenchkiss |
November 11, 2016, 11:35am |
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Fledgling Member
Posts: 6
Time Online: 4 hours 11 minutes
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Hi from France,
I was planing to mount brake discs on my 1600R...so i find how now ! Many thanks for your drawings and pics, they will hep me in my mount ! i have ordered yet the caliper and discs on Alipress this day...
So i have to "traduct" all the measurement in métrique ! perhaps the program you use can make it automaticly ? if you can edit your PDF here with this it will be GREAT !
I'm finishing mounting a Simonini Victor 1 engine on my plane, it replace the antic 447....a lot of work this winter !
Have a nice day
And sorry for my bad english.....
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texasbuzzard |
November 11, 2016, 1:08pm |
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airbike Buzzard Ace
Posts: 1,238
Time Online: 8 days 23 hours 51 minutes
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hey your English is a lot better than my French. you have a great day too.
monte |
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ulbuilder |
November 12, 2016, 1:33am |
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N349LE Ace
Posts: 302
Time Online: 8 days 20 hours 59 minutes
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Frenchkiss, if you get an account created on [url]OnShape.com[/url] I can share my drawings with you. I *think* you could convert to metric without much work.
I think all I need is your email address that you use for your OnShape account and I can share the file with you. |
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Frenchkiss |
November 13, 2016, 7:15pm |
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Fledgling Member
Posts: 6
Time Online: 4 hours 11 minutes
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Hi,
i have create an account on oneshape,
i send you my mail by private message
many thanks for this |
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PUFF |
November 14, 2016, 12:45pm |
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Ace
Posts: 1,518
Time Online: 34 days 6 hours 18 minutes
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oh and pictures of your plane too... |
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ulbuilder |
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N349LE Ace
Posts: 302
Time Online: 8 days 20 hours 59 minutes
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Now that I have about 30 flight hours I can report how well the brakes work.
The brakes can hold the airplane stationary, on grass, at full throttle with my Kawasaki 440a. It does take significant pressure on the brake lever.
I've used them to slow down after landing without issue.
Nothing has broken or bent.
They do require occasional adjustment, I think mostly because the adjustment screws on the calipers loosen from engine vibration. I did have a shaking, rattling and rolling Hirth F33 the first 20 hours....
I have a locking brake lever on my stick. Very nice when starting the engine or idling on the taxiway waiting for traffic to clear the runway.
I think the weakest link in the design is the rotor adapters but so far they are working great.
I've had issues with tire clearance and cannot run the tires I like best. But had I had those tires before cutting the axle I could have made the axle a little longer to accommodate some spacers to resolve the issue. If my axle was just 1/2" longer..... |
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ITman496 |
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Ace
Posts: 411
Time Online: 1 days 23 hours 31 minutes
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Out of curiosity, since I too have a 440a...
I have band brakes. Can they hold the plane stationary at full power?
What are the pros of upgrading to these disks? I happen to have all this hardware from a gokart before I converted it to hydraulic brakes.
Also, how does the plane not tip forwards when under brakes at full power? Elevator keeps the tail down? |
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ulbuilder |
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N349LE Ace
Posts: 302
Time Online: 8 days 20 hours 59 minutes
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My max is tricycle gear so no tipping issues for me.
If I already had band brakes, don't see any compelling reason to switch to disk brakes. I look at this as an option for a new build.
I am able to hold the airplane at full power. But it does take considerable pressure on the brake lever. |
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bob.hood |
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Ace
Posts: 225
Time Online: 4 days 18 hours 40 minutes
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ulbuilder,
The only thing I would add would be a pair of brake 'noodles' from a bicycle to turn the brake cables. It's what I've done on my 'max as you can see in the first two pics below. I used the original band brakes to save time trying to work out clearances, etc, and just made up some new brackets out of 6082 bar. However, one other thing I did was extend the axle mounting brackets from the two bolt pattern to an amended three bolt pattern as can be seen in the last picture. This means the max weight can be increased up to 590lbs according to the plans.
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ulbuilder |
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N349LE Ace
Posts: 302
Time Online: 8 days 20 hours 59 minutes
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I've considered the three bolt mounts ever since I saw a picture of them here long ago.
The noodle is a great suggestion, thanks. |
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joe.scalet |
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Flight Leader
Posts: 155
Time Online: 2 days 1 hours 58 minutes
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A note of caution: You do not want really effective brakes on a conventional gear airplane (tail dragger). If you fly any of the Champs, Cubs, Luscombe's, etc. you will be disappointed in the brakes, this is part of the design. You need to think way ahead of the aircraft and anticipate where you will turn or stop. Great brakes can easily put you on your nose or over on your back. If you have tricycle gear, good brakes are indeed and asset. Joe - 800+ hours in tail draggers. |
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joe.scalet |
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Flight Leader
Posts: 155
Time Online: 2 days 1 hours 58 minutes
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Also, avoid any brakes that can "grab"! |
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flyguyeddy |
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Fledgling Member
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Time Online: 2 days 7 hours 42 minutes
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AlexW |
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Fledgling Member
Posts: 14
Time Online: 8 hours 41 minutes
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Nice looking mount for the brakes, I too have purchased disc brake calipers for my tandem airbike build. I purchased mine through a bike parts online store, I was going to go with hydraulic actuation but felt the cable variety would be ample for what i needed.
I will post some pictures once i have finised the cad for mine.
On another note, in terms of cad software fusion 360 by autodesk is also free for hobby / personal use. I highly recommend it, particularly if you are using the cad in conjunction with a cnc router or 3d printer.
Cheers Alex |
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