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Seeking Aileron Pulley Bracket Advice

Posted: Thu Mar 01, 2018 9:15 pm
by r1200gsDave
I am working on the aileron pulley bracket this weekend for my Pietenpol. I am seeking any advice you might have.

Re: Seeking Aileron Pulley Bracket Advice

Posted: Thu Mar 01, 2018 10:29 pm
by taildrags
r1200GSDave-

I have never built this bracket myself, so there isn't much that I can offer. However, seeing that the plans call for brazing the inner brackets to the main "U" pulley holder bracket, I have read about problems with brazing 4130 steel and cracks developing. If you are making your parts out of 4130 and you can weld this rather than brazing it, that would be better but if not and since this is not primary structure, it probably doesn't make any difference.

Re: Seeking Aileron Pulley Bracket Advice

Posted: Fri Mar 02, 2018 10:07 pm
by B Wilson
Don't mean to hijack your thread, but I am also building these and I have a question. I am using 4130 and plan to gas weld them, but it looks like you need to put the attachment bolts through the bracket before you weld them up. Any thoughts from anybody?
Thanks,
Brent

Re: Seeking Aileron Pulley Bracket Advice

Posted: Fri Mar 02, 2018 10:11 pm
by B Wilson
Don't mean to hijack your thread, but I am also building these and I have a question. I am using 4130 and plan to gas weld them, but it looks like you need to put the attachment bolts through the bracket before you weld them up. Any thoughts from anybody?
Thanks,
Brent

Re: Seeking Aileron Pulley Bracket Advice

Posted: Sat Mar 03, 2018 3:38 pm
by taildrags
Brent; if the part is held up to the wood, you're right... it will not be possible to insert the bolts with the part assembled. However, if the bolts are inserted into the holes in the metal and they're not a tight fit, the part could then be moved into position and the bolts pushed through the holes in the wood. Good luck getting a socket or wrench on the bolt heads though. the only way to hold the bolts from turning will be to jam a screwdriver or chisel in there and then tighten the nut.

This is one of those parts that you might think about welding the bolts into the U-bracket before welding on the inner pulley brackets and then it's all good.

Re: Seeking Aileron Pulley Bracket Advice

Posted: Sat Mar 03, 2018 11:07 pm
by B Wilson
Thanks Oscar
I think inserting them and welding them to the u bracket is a good idea.
Keep up the good work. I really appreciate your commitment to replying to everybody's questions. It keeps things interesting on our site.
BW

Re: Seeking Aileron Pulley Bracket Advice

Posted: Thu Mar 15, 2018 8:41 pm
by r1200gsDave
This is one of those deceivingly "simple" parts that take an enormous amount of time. I have a pretty good prototype and 5 scrap parts.....

Welding the thin 4130 is above my skill. But I have found a workable design that I can make.

The bolt does not need to welded in place. You will have to temporarily bend the inner tab in to fit a nut driver on it.

Re: Seeking Aileron Pulley Bracket Advice

Posted: Thu Mar 15, 2018 8:50 pm
by r1200gsDave
This is a horrible mess.... none of these are airplane parts. Just me trying to figure out how to make the part and work on my welding skills....

The best I got to is a backwards L that I flat weld in place.

Re: Seeking Aileron Pulley Bracket Advice

Posted: Fri Mar 16, 2018 6:22 pm
by r1200gsDave
I have two winners! the "L" version worked well and I am ready to powder coat the parts tomorrow.

Re: Seeking Aileron Pulley Bracket Advice

Posted: Fri Mar 16, 2018 9:09 pm
by r1200gsDave
Here are some more photographs of how I make the bracket.

As usual It took me a days to figure out how I would finally make the part. now that i have made it I can make it in about 30 minutes.
However I still cannot make two identical parts. They are really similar, but hand made parts still have slight variances.

Peace

Re: Seeking Aileron Pulley Bracket Advice

Posted: Tue Jun 18, 2019 9:35 pm
by at7000ft
P1010459.JPG
I tig welded mine, and in order to get the bolt in after welding I ground the hole out a little so the bolt could be inserted at a slight angle.

Rick H

Image
https://drive.google.com/open?id=0B1Y1j ... DFSeno5VTg

Re: Seeking Aileron Pulley Bracket Advice

Posted: Thu Jun 20, 2019 7:46 pm
by Lownslow
Thats what I did too.