Brake Cylinders

Step 7 Installing Master Brake Cylinders

I bought a complete set of Matco brakes, calipers, master cylinders, reservoirs and etc. Given I'm also using Dennis Oelmann rudder pedals, the master cylinder install is different than the plans. You can find a drawing that covers the install (albeit with Cleveland master cylinders/reservoirs) in Cozy MkIV newsletter #43, page X.

These mount points are similar to the newsletter install, however, I've cut through the 'glass on the nose floor with my Fein tool. I've also 'routed' the foam below so the channel will sit flush with the floor.

This installation involved a lot of trial and error fitting to make sure I had the cylinder mounts in the exact right place before I glassed over them. I used a CAD drawing, test fitting like this, pencil marks, the list goes on. I tried to account for the different fore and aft position of each side (left seat pedals further forward), to get them as close to the NG-30s as possible without interference and to have the pedal perpendicular to the floor when the cylinders were neutral and the pedals mid-position rudder-movement wise.

Here's a shot of the overall install, right side. Cozy rudders only deflect outward, so I've installed the cylinder with full extension of the slider assembly.

Once I was sure the mounts were in the right place I sanded with 36 grit and floxed them in place. I drilled a ton of holes in the bottoms of the mounts, to allow better grip for the flox.

Here's one side after the fiberglass layup was installed over the flox and the mount. I used one large piece of glass per layer, having made a nice pattern out of paper, but cut slots in it for the sides of the mount channels. I'm hoping I won't have any trouble with these mounts flexing or trying to come out when I stand on the brake pedals hard for that deer that just ran across the runway....

Same procedure, other side. This picture gives a better view of the geometry.

I decided the best place for the reservoirs was further forward on either side of the NG-30s. I hope this isn't too hard to get to I need to put brake fluid in them.

To install these I made up some 1/8" aluminum plates with nutplates riveted on. A couple AN-3 bolts on the reservoir mounts and I was in business. These plates got alodined, per the plans mod, for corrosion protection.

The left pedal, outside, in full forward brake pressure, hits the outside of the fuselage. Given there is about an inch and a half of foam outside the inner glass, I decided to make a depression to allow for this. I'll glass over this again once the outside glass layup is done, and adjust its size for proper fit.

That completes the master cylinder install.

Next step is Completion of the Nose Gear.