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Install a blind rivet in the #30 hole.
Put the WD-804-L & -R Rudder Pedals in place on the WD-816 Rudder Slide (See Exploded Reference View”
and “Isometric View”, DWG 81). Check that both rudder pedals pivot smoothly with no binding. Hone the rud-
der pedals as needed so that they pivot smoothly.
Place an F-874 Rudder Pedal Slide Block on the outboard ends of the WD-816 Rudder Slide (See “Isometric
View”, DWG 81).
NOTE: The wider portion of the block faces down.
Position the blocks with just enough
clearance to the WD-804-L & -R Rudder Pedals so that they still pivot smoothly with no binding.
Clamp the bottom flange of the WD-818 Rudder Socket to the edge of a flat worktable with the bottom surface
of the two F-874 Rudder Pedal Slide Blocks resting flush on the table surface.
Match-Drill #12 the hole in the forward side of the F-874 Rudder Pedal Slide Blocks into one wall of the WD-816
Rudder Slide tube (do not drill through both walls of the tube). Insert a short AN3 bolt in the hole to maintain
alignment, then match-drill #12 the hole in the aft side of the rudder pedal slide blocks into the opposite wall of
the rudder slide tube.
Unclamp the WD-818 Rudder Socket from the table edge, then remove the F-874 Rudder Pedal Slide Blocks
and the WD-804-L & -R Rudder Pedals from the WD-816 Rudder Slide. Deburr the #12 holes match-drilled in
the two previous steps.
Apply a thin coating of light grease to the interior of the tube on the WD-804-L & -R Rudder Pedals, and the out-
side surface of the tube on the WD-816 Rudder Slide. Reinstall the left and right rudder pedals on the rudder
slide.
Bolt the two F-874 Rudder Pedal Slide Blocks in place on the WD-816 Rudder Slide (See “Isometric View”,
DWG 81).
Clamp the bottom flange of the WD-818 Rudder Socket to the edge of a flat worktable. Slide the WD-816 Rud-
der Slide fully forward so that it touches the F-8107 Slide Collar.
With the two F-874 Rudder Pedal Slide Blocks flush to the worktable surface, match-drill 1/4 through the top of
the WD-817 Rudder Slide Bar tube using the F-8103E Lock Pin hole in the WD-816 Rudder Slide as a guide.
Slide the WD-816 Rudder Slide to the aft most position against the WD-818 Rudder Socket.
With the two F-874 Rudder Pedal Slide Blocks still flush to the table surface, match-drill 1/4 through the top of
the WD-817 Rudder Slide Bar tube using the F-8103E Lock Pin hole in the WD-816 Rudder Slide as a guide.
Unclamp the WD-818 Rudder Socket, then remove it and the WD-816 Rudder Slide from the WD-817 Rudder
Slide Bar.
Use a sharp scribe to mark the WD-817 Rudder Slide Bar with additional hole positions approximately one inch
on center between the two holes drilled previously.
Reinstall the WD-816 Rudder Slide and WD-818 Rudder Socket, and clamp to the table as before.
Match-Drill 1/4 the other hole positions by centering each scribe mark in the F-8103E Lock Pin hole and then
using the lock pin hole as a guide for drilling.
Unclamp the WD-818 Rudder Socket, then remove it and the WD-816 Rudder Slide from the WD-817 Rudder
Slide Bar.
Deburr the 1/4 holes drilled in the WD-817 Rudder Slide Bar.
Reassemble the WD-816 Rudder Slide and WD-818 Rudder Socket onto the WD-817 Rudder Slide Bar.
Deburr and smooth the edges of the WD-820-L & -R Left and Right Brake Pedal Assemblies (See “Isometric
View”, DWG 81).
Final-Drill #12 the 3/16 hole in the outboard leg of the WD-804-L & -R Rudder Pedals. Deburr the two holes
drilled in this step (See DWG 81).
Final-Drill #12 the 3/16 hole in both lugs used for mounting the bottom of the brake master cylinders to the WD-
816 Rudder Slide tube. Deburr the two holes drilled in this step.
Attach the WD-820-L & -R Brake Pedal Assemblies to their respective WD-804-L & -R Rudder Pedals. Use a
combination of thick and thin washers as spacers to minimize slop at the pivot points. The Brake Pedal Assem-
blies must move freely with no friction to prevent the brakes from dragging.
Install the brake line fittings on the two brake master cylinders. Orient them as shown in “Front View”, DWG 83.
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Mount the bottoms of the brake master cylinders to the WD-816 Rudder Slide (See “Isometric View”, DWG 81).
Mark the master cylinder bolt hole position on the WD-820-L & -R Brake Pedals (See “Drilling WD-820”, DWG
81).
NOTE: This hole location provides a brake pedal angle as shown in “Side View” on DWG 81. If you
desire a different brake pedal angle adjust this hole location. Someone with a much larger than average
foot size might prefer the brake pedals to be tilted further forward to prevent inadvertent brake applica-
tion when moving the rudder pedals to the extreme ends of the travel range.
Use a #30 bit to drill a pilot hole in the WD-820-L Brake Pedal at the mark made in the previous step. Final-Drill
the hole #12.
Attach the top of the master cylinder to the WD-820-L Brake Pedal (See “Detail C”, DWG 81).
Clamp a small board across the aft side of both inboard, vertical tubes of the WD-804-L-1 & -R-1 Rudder Ped-
als to align them with each other.
Position the WD-804-L-1 & -R-1 Rudder Pedals so that they are vertical as shown in “Side View”, DWG 81.
Insert a 3/16 drill bit into the bolt hole in the top of the right master cylinder. Position the WD-820-R Brake
Pedal so that it is aligned with the WD-820-L Brake Pedal. Check that the tip of the drill bit aligns with the bolt
hole location mark on the right brake pedal. If it does not, mark a new location using the point on the drill bit.
NOTE: The goal is to drill a hole in the right brake pedal, as close as possible to the original mark, so
that the pedals are aligned with each other.
Drill the brake cylinder attach hole in the WD-820-R Brake Pedal by first pilot drilling #30, then final-drilling #12.
Attach the second master cylinder to the WD-820-R Brake Pedal (See “Detail C”, DWG 81).
Double check that both brake pedals operate smoothly, and that when depressed and released, the brake cylin-
ders re-extend fully.
Break apart the six F-8103C Release Spacers from each other (See “F-8103C Release Spacer”, DWG 81).
Final-Drill #30 the 1/8 holes in each of the release spacers. Remove any portion of the connect tabs from the
six parts, smooth and deburr the edges, and deburr the #30 holes.
Deburr the two F-8103B Lifter Plates and the plate on the F-8102 Release Cable. Final-Drill #30 the 1/8 holes
in the two lifter plates and the release cable plate. Deburr the #30 holes in the three parts.
Rivet the two F-8103B Lifter Plates, six F-8103C Release Spacers, and F-8102 Release Cable plate together
with the parts positioned as shown in “F-8103 Release Assembly”, DWG 81.
Make the F-8103E Lock Pin as shown in “F-8103E Lock Pin”, DWG 81.
Assemble the F-8103E Lock Pin using the steps shown in “F-8103E Lock Pin Assembly”, DWG 81.
NOTE: The
roll pin must be pressed fully through the hole in the lock pin, and then pressed back the other direc-
tion to center it. This will make the diameter of the roll pin more constant and prevent the lock pin from
binding in the guide.
A small bench vice can be used to press the roll pin through the lock pin. Use a small
wood block with a 1/8 hole to allow for pressing the roll pin beyond the opposite side of the lock pin.
Drill a hole in the F-8102A Handle as shown in “F-8102A Handle”, DWG 81.
Install the F-8103 Release Assembly on the WD-816 Rudder Slide using the hardware shown in “F-8103 Re-
lease Assembly”, DWG 81.
Cut a slot in the F-8102B Fairlead Insert as shown in “Detail B”, DWG 81. Use a small C-clamp to press the
fairlead insert into the fairlead on the WD-818 Rudder Socket.
Route the free end of the F-8102 Release Cable through the F-8102B Fairlead Insert (See “Isometric View”,
DWG 81).
Move the rudder pedals to the most forward position. Cut the cable to desired length allowing approximately
5/8 extra for tying a knot in the end.
Move the rudder pedals to the aft most position.
Insert the free end of the F-8102 Release Cable into the hole drilled in the F-8102A Handle (See “F-8102 Cable
Assembly”, DWG 81). Pull the wire out through the side of the handle and tie a single half-hitch knot in the end.
Pull on the handle to pull the wire back inside and tighten the knot.