X-Virus-Scanned: clean according to Sophos on Logan.com Return-Path: Received: from [24.25.9.103] (HELO ms-smtp-04-eri0.southeast.rr.com) by logan.com (CommuniGate Pro SMTP 5.0) with ESMTP id 810421 for flyrotary@lancaironline.net; Tue, 01 Nov 2005 08:50:25 -0500 Received-SPF: pass receiver=logan.com; client-ip=24.25.9.103; envelope-from=eanderson@carolina.rr.com Received: from edward2 (cpe-024-074-025-165.carolina.res.rr.com [24.74.25.165]) by ms-smtp-04-eri0.southeast.rr.com (8.12.10/8.12.7) with SMTP id jA1Dnc1u012675 for ; Tue, 1 Nov 2005 08:49:38 -0500 (EST) Message-ID: <000a01c5deeb$20097a20$2402a8c0@edward2> From: "Ed Anderson" To: "Rotary motors in aircraft" References: Subject: High Energy Brake Up grade Date: Tue, 1 Nov 2005 08:49:48 -0500 MIME-Version: 1.0 Content-Type: multipart/alternative; boundary="----=_NextPart_000_0007_01C5DEC1.36F57EC0" X-Priority: 3 X-MSMail-Priority: Normal X-Mailer: Microsoft Outlook Express 6.00.2900.2180 X-MIMEOLE: Produced By Microsoft MimeOLE V6.00.2900.2180 X-Virus-Scanned: Symantec AntiVirus Scan Engine This is a multi-part message in MIME format. ------=_NextPart_000_0007_01C5DEC1.36F57EC0 Content-Type: text/plain; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable Hi David, I started out with the standard Van's 500 wheels and brakes as provided = in the kit for the RV-6A. After my brake failure incident, I did some = research about an upgrade kit I heard about on the RV list. The = Cleveland folks indicate the upgrade increases the stopping power = (energy dissipation by 30-40%). I found out that Aircraft Spruce = offers a upgrade kit for Approx $300. =20 The standard brake system is undoubtedly OK when the aircraft weights in = at/under Van's recommendation - but when the aircraft is heavier and = lands a bit faster, I feel the standard brakes leave very little = reserve. A couple of hard stops and you will find the brakes beginning = to slip. In any case, I wanted a bit of a reserve in stopping power. Well, I did further research and found that the upgrade consisted of: 1. Thicker rotors (twice as thick as the one that comes with the kit) - = this is the key component as it absorbs and dissipates the heat better. 2. A 1/8" thick spacer/shim for the calipers 3. Two longer bolts to accommodate the additional thickness of the = spacer. 4. The standard brake pads continue to be used. As an aside, I found that the standard brake fluid has a flash point of = only 240F, so I went to a 450F flash point brake fluid - compatible with = the old fluid and seals.=20 I also replace the kit brake lines with -3 (1/8") brakelines with ss = braid and Teflon lining inside, they give a much firmer feel to the = brakes. Again, this is not necessary - just my personal preference. I found FAA approved rotors for approx $75.00 each for a total of $150, = so I decided to save $150 over the cost of the Kit from Spruce and = ordered them. When I got the rotors, I realized I needed the spacer/shim for the = caliper to accommodate the thicker rotor. So I figured how much can a = 1/8" thick piece of aluminum with two bolt holes in it cost? Well, they = cost $84.00 each!!!!!. So, I made my own out of a 1/8" thick piece of = 6061T6 aluminum plate saving $160. I could not believe this shim cost = more than the rotors but they did. I anodized the plate for corrosion = protection. You can make your own with a drill press, a hacksaw and a = file. A bandsaw makes it a piece of cake. If you retrofit you will find that the thicker rotor will more than = likely require you to space the wheel pant bracket out further with = longer tube spacers on the bolts holding the bracket - else the rotor = will rub against the bracket. While I was at it, I remade the wheel = pant brackets out of 0.05 SS. Here are the part numbers of interest. If you want to buy Aircraft Spruce's Complete upgrade kit, their part = number is #199-93 UPGRADE KIT - For #199-102 standard wheels and brakes. Upgrades = current 40-78B/ 30-9 to new 40-230/30-181 specs. Consists of #66-106 = linings, discs, shims, bolts, rivets and nameplates for two wheels and = brakes. $295.65. This kit has everything you need. This kit is for the type wheels brakes on the RV series there are two = other kits for Long EZ and Cozy but they are much more expensive as they = include the wheels as well. Now if you want to roll your own upgrade here are the part numbers you = will need. 2 - Brake Rotors (RAPCO) from Chief Aircraft Part number RA 164-09900 = $79.95 Each http://www.chiefaircraft.com/cgi-bin/air/hazel.cgi?action=3Dserve&item=3D= /Aircraft/Brakes/BrakeDiscs.html 4 - Longer bolts (2 for each wheel) to accommodate shim thickness = Part Number AN4H-16A (This has the bolt head drilled for safety wire) 2 - 1/8" thick 6061T6 plate. approx 3"x1" (I used a brake pad to give = me the curve needed to match the edge of the rotor) in which you will = need to drill two 3/16" holes to capture the two AN4H-16A bolts. =20 As I mentioned you will probably need to use longer spacers for the = wheel pant brackets, I think I went from 1/2" to 3/4" but you will need = to do it so there is approx 1/8" Min between the rotor and wheel pant = bracket when installed. You can find the rotors at other sources, but Chief had the best price = and I had deal with them before. Here are a few links to websites with discussion on the higher energy = brake system Good write up on the higher flash point brake fluid = http://www.fly-web.org/EAA-Chapter493/news/sep04new.pdf Cleveland brakes - the 199-93 upgrade kit description starts on page 9 = - top of page http://www.parker.com/ag/wbd/Cleveland/pdf/wb02b.pdf Here is the best write up on the upgrade even though its in context of = the FALCO aircraft http://www.seqair.com/skunkworks/LandingGear/Notes/Notes.html Any question, just shoot me a line. Ed A ----- Original Message -----=20 From: David Carter=20 To: Rotary motors in aircraft=20 Sent: Monday, October 31, 2005 10:04 PM Subject: [FlyRotary] Brake size (was Re: Shady Bend Report Ed, I've missed what kind of "brake upgrade" you did. If the original = Van's/Cleveland? brakes didn't have enough energy absorption "power", = what did you replace them with? Are you still using the stock Van's = size wheels and tires or something bigger in dia to allow for bigger = brake disc and pads? What kind of options do we have for "size" of brakes? David ----- Original Message -----=20 From: Ed Anderson=20 To: Rotary motors in aircraft=20 Sent: Monday, October 31, 2005 9:26 AM Subject: [FlyRotary] Re: Shady Bend Report Hope to see you there next year, Mark. =20 Sounds like you are making good progress (when visitors are = not present I was wondering about your brake size, I am real happy with = my brake up-grade, just feels like I have more authority over where the = aircraft goes. I calculated the ft-lbs of energy required to stop my = RV-6A from 60 MPH and decided that the old brakes were marginal - = especially with my somewhat heavier aircraft. =20 . Ed A ------=_NextPart_000_0007_01C5DEC1.36F57EC0 Content-Type: text/html; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable
Hi David,
 
I started out with the standard Van's 500 wheels = and=20 brakes as provided in the kit for the RV-6A.  After my brake = failure=20 incident, I did some research about an upgrade kit I heard about on the = RV=20 list. The Cleveland folks indicate the upgrade increases = the stopping=20 power (energy dissipation by 30-40%).   I found out that = Aircraft=20 Spruce offers a upgrade kit for Approx $300. 
 
The standard brake system is undoubtedly OK when = the=20 aircraft weights in at/under Van's recommendation - but when the = aircraft is=20 heavier and lands a bit faster, I feel the standard brakes leave very = little=20 reserve.  A couple of hard stops and you will find the brakes = beginning to=20 slip.  In any case, I wanted a bit of a reserve in stopping=20 power.
 
 
Well, I did further research and found that the = upgrade=20 consisted of:
1.  Thicker rotors (twice as thick as the = one that=20 comes with the kit) - this is the key component as it absorbs and = dissipates the=20 heat better.
2.  A 1/8" thick spacer/shim for the=20 calipers
3. Two longer bolts to accommodate the = additional=20 thickness of the spacer.
4.  The standard brake pads continue to be=20 used.
 
As an aside, I found that the standard brake = fluid has a=20 flash point of only 240F, so I went to a 450F flash point brake fluid -=20 compatible with the old fluid and seals.
 
I also replace the kit  brake lines with -3 = (1/8")=20 brakelines with ss braid and Teflon lining inside, they give a much = firmer feel=20 to the brakes.  Again, this is not necessary - just my personal=20 preference.
 
I found FAA approved rotors for approx $75.00 = each for a=20 total of $150, so I decided to save $150 over the cost of the Kit from = Spruce=20 and ordered them.
 
When I got the rotors,  I realized I = needed the=20 spacer/shim for the caliper to accommodate the thicker = rotor.  So=20 I  figured how much can a 1/8" thick piece of aluminum with two = bolt holes=20 in it cost?  Well, they cost $84.00 each!!!!!.   So, = I made=20 my own out of a 1/8" thick piece of  6061T6 aluminum plate saving=20 $160.  I could not believe this shim cost more than the rotors but = they=20 did.  I anodized the plate for corrosion protection.  You can = make=20 your own with a drill press, a hacksaw and a file.  A bandsaw makes = it a=20 piece of cake.
 
If you retrofit you will find that the thicker = rotor will=20 more than likely require you to space the wheel pant bracket out further = with=20 longer tube spacers on the bolts holding the bracket - else the rotor = will rub=20 against the bracket.  While I was at it, I remade the wheel pant = brackets=20 out of 0.05 SS.
 
Here are the part numbers of = interest.
 
If you want to buy Aircraft Spruce's Complete = upgrade kit,=20 their part number is
 
#199-93 UPGRADE KIT - = For=20 #199-102 standard wheels and brakes. Upgrades current 40-78B/ 30-9 to = new=20 40-230/30-181 specs. Consists of #66-106 linings, discs, shims, bolts, = rivets=20 and nameplates for two wheels and brakes.   $295.65.  = This kit=20 has everything you need.
 
This kit is for the type wheels brakes on the RV = series=20 there are two other kits for Long EZ and Cozy but they are much more = expensive=20 as they include the wheels as well.
 
Now if you want to roll your own upgrade here = are the part=20 numbers you will need.
 
2 - Brake Rotors  (RAPCO) from Chief = Aircraft Part=20 number RA 164-09900 = $79.95=20 Each
 
http://www.chiefaircraft.co= m/cgi-bin/air/hazel.cgi?action=3Dserve&item=3D/Aircraft/Brakes/BrakeD= iscs.html
 
 
4 - Longer bolts (2 for each wheel) to = accommodate=20 shim  thickness        =  =20 Part Number AN4H-16A (This has the bolt head drilled = for safety=20 wire)
 
2 - 1/8" thick 6061T6 plate.  approx 3"x1" = (I used a=20 brake pad to give me the curve needed to match the edge of the rotor) in = which=20 you will need to drill two 3/16" holes to capture the two = AN4H-16A=20 bolts. 
 
As I mentioned   you will probably = need to use=20 longer spacers for the wheel pant brackets, I think I went from 1/2" to = 3/4" but=20 you will need to do it so there is approx 1/8" Min between the rotor and = wheel=20 pant bracket when installed.
 
You can find the rotors at other sources, but = Chief had=20 the best price and I had deal with them before.
 
Here are a few links to websites with discussion = on the=20 higher energy brake system
 
Good write up on the higher flash point brake = fluid http://w= ww.fly-web.org/EAA-Chapter493/news/sep04new.pdf
 
Cleveland brakes  - the 199-93 upgrade kit=20 description starts on page 9 - top of page
 
http://www.= parker.com/ag/wbd/Cleveland/pdf/wb02b.pdf
 
 
Here is the best write up on the upgrade even = though its=20 in context of the FALCO aircraft
 
ht= tp://www.seqair.com/skunkworks/LandingGear/Notes/Notes.html
 
Any question, just shoot me a line.
 
Ed A
 
 
----- Original Message -----
From:=20 David=20 Carter
Sent: Monday, October 31, 2005 = 10:04=20 PM
Subject: [FlyRotary] Brake size = (was Re:=20 Shady Bend Report

Ed, I've missed what kind of "brake = upgrade" you=20 did.  If the original Van's/Cleveland? brakes didn't have enough = energy=20 absorption "power", what did you replace them with?  Are you = still using=20 the stock Van's size wheels and tires or something bigger in dia to = allow for=20 bigger brake disc and pads?
 
What kind of options do we have for = "size" of=20 brakes?
 
David
----- Original Message -----
From:=20 Ed Anderson
To: Rotary motors in = aircraft=20
Sent: Monday, October 31, = 2005 9:26=20 AM
Subject: [FlyRotary] Re: = Shady Bend=20 Report

Hope to see you there next year, Mark.  =
 
<snip> Sounds like you are making good = progress=20 (when visitors are not present I was = wondering about=20 your brake size, I am real happy with my brake up-grade, just feels = like I=20 have more authority over where the aircraft goes.  I calculated = the=20 ft-lbs of energy required to stop my RV-6A from 60 MPH and decided = that the=20 old brakes were marginal - especially with my somewhat heavier=20 aircraft. 
<snip>.
 
Ed A
 
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