Total Build Time: 745 hours.
For the brake system I intended to use the system as called for in the plans, with an addition of a turnbuckle to allow for easy brake cable tension adjustments.
Sourcing the parts for the brake system ended up being more of a chore than I’d imagined. There were several parts that I needed to hunt for to find. For example, the brake cable housing I ended up getting at a bicycle shop (I could not find it in any hardware or auto supply stores in my area.)
I found the screen door rollers at home depot, and a turnbuckle at ace hardware. I needed a single left-hand threaded nut in order to lock the turnbuckle position, and none of the big box hardware stores carried them. Also worth mentioning that I couldn’t source any left-hand threaded nut smaller than 1/4″, so that’s the size turnbuckle I used.
I’ll note however that even though those nylon rollers seem to fit the description in the plans, they are totally inadequate as they deform too easily.
I found some metal rollers to use instead, although they were slightly larger and had a smaller hole than the plans called for. I made some minor modifications to make it fit.
To locate the holes for the brake cables to pass through the firewall, i used 2 magnets.
I fabricated the brake handle and associated parts and assembled them.
Finally, here is a picture of the turnbuckle I used to allow for easy tension adjustments.
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Hi David,
I had no luck at all in selling my Waiex fuselage, so it looks like I will keep working on it and you never know, I may even get it finished. Sonex leaves a lot to be desired in as though, like yourself, have to out source hard to find parts, as the brake cable and the brass door rollers, ect. Now I have the question; will 15 feet of brake cable be adaquate, and shall I order 1/8 stainless. I am going to copy your idea and use a turnbuckle to adjust cable tension. Thanks for that idea.
AL
I also used a 1/4 inch turnbuckle because the next size smaller looked to be too weak to withstand the pull
AL