Europa #435 G-RODO Build Journal - 2019 03

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day	notes	hours
2	Feel that the additional clearance offered by re-boring the rudder pedal bearing blocks is going to be really worthwhile. Get out the 600mm x 22mm x 12mm piece of Carp Tufnol and check its straightness against a girder level - looks perfect. Start to put it in the milling vise to check the X-axis trueness and then realise that it will block access to the slot-head fixing screws. Can't find any 25mm M6 hex bolts so cut off lengths from a couple of longer screws to act as studs. Clean up the cut end threads with M6 die. Remove each of the slotted pan screws in turn and replace them with the studding. Fit larger washers and hex nuts.	3044.2
12	After seeing ( Matronics e-mail list, 10 March) Bud Yerly's T-handle solution to the awkward choke knob, have a look online for the type of T-handle he used, but although many pi-shaped ones (ie 2 legs) turn up, can't find any actual T-shaped ones. Remove the choke knob & locknut for investigation. The straight part of the knob is about 25mm long (enough to get fingers around) and the end is about 0.9" diameter. From aluminium stock, I have a piece of hex bar 3/8" AF which would do for the shaft, and a 3/4" diameter round rod which would be good for the cross-piece. There is 13mm depth of tapped hole in the existing knob, and 15mm of thread on the choke shaft. The locknut is 3mm thick, leaving 12mm of thread for engagement. At the Gloster Strut , David Joyce passes on to me the leftover bits of stainless steel from his attempts at making the firewall. I may now have enough to make a patch in the firewall that will only be single-thickness in the critical area, and can be wrapped tightly around the LG diagonal tube. Not sure how hard it will be to attach the rest of the firewall to this proposed patch.
13	Draw up the proposed T-handle for the choke in CADintosh . Order 1/4" x 26TPI BSF taper & plug taps, and a die for good measure, from Tracy Tools .
14	After some fruitless research on engraving and etching, order on eBay a set of 8mm letter punches for labelling the choke T-handle.
15	1/4" x 26TPI BSF taps and die delivered from Tracy Tools . Clear up the metal stock into the 2 bins. Put the DTI in the mill chuck and set the piece of SRBF on wavy parallels in the milling vise with the edge protruding above the top of the vise. Run the X-feed back & forth, tapping the vise with a lead weight to bring the SRBF parallel with the mill table. After several sweeps it seems pretty reasonable, with about 0.03mm movement on the DTI over about 150mm travel. Tighten down the holding nuts on the studs and re-check - no change. Take out the SRBF and put a large 1-2-3 block in the vise. It shows about 0.01mm variation over the long edge, so I am satisfied with that. Hacksaw a piece about 29mm off the 3/8" hex aluminium bar, and a piece about 52mm off the 3/4" round bar. Hefting the latter in my hand, it seems quite heavy. Boring out the ends would lighten it significantly and seems worthwhile. Edit the CADintosh drawing to show the ends of the T-piece bored out.
16	Letter punches delivered. In order to check exactly where the space for the firewall sheet is most critical, start to re-install the aft rudder pedal shaft. Get out the CS22 & CS23 bearing blocks, the rudder pedals and the CS21 horns. To save having to flip pages in the paper manual between the firewall & the rudder pedal installation, print out pages 22-8 to 22-10 from the PDF. CS22 & CS23 are marked (CS22 II & III; CS23 I & IIII) to keep the correct halves together but I am not sure which way round they go on the footwell. Have a look in the journal but can't find any explicit record of that. I do seem to recall that the marks were put on the forward face, and that I was at port and IIII was at starboard. Try out all of them on the starboard footwell and III and IIII do seem to fit best. Fit CS18 (starboard aft) and XCS19P (port aft) rudder pedals through the holes in the sides of the footwells. Fit CS18 to starboard footwell with CS22 (III) and CS23 (IIII). The polyethylene sheet insulating curtain is not staying tucked up behind the long pieces of metal, so put a screw-eye in the roof timber and tie the polyethylene up properly to that. Can't reach port footwell by reaching over the firewall - I will have to clear the stuff from the port seat so I can get in there.	3046.2

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