Ok, you all know if you are keeping up, I scored a pair of B-737 rudder pedals on eBay for about 200 bucks. So the first thing I have to do is take the pedals apart and clean them. The parts diagrams and part numbers come from the Boeing 300/400/500 IPC (Illustrated Parts Catalog), section 27-21-00-36 page 0.

Analysis / Plan

  • Rudder Pedals

As you can see from the picture the rudder pedal tubes have been cut off, and the attachment point by the peddle's  receiver which is drilled through for the peddle, also there are four (4) rivets per peddle two per side, which will have to be removed and then replaced when the new tube's OD has been reduced on a lathe, and to really complicate this the through-hole is ~1.48" and electrical EMT conduit size is 1.25" which has a nominal OD of 1.51" with a .065 wall thickness. In real life, this tube is a swedge tube, but since this is priced as unobtainium I will fake it by printing the swedge (neck) then side a larger piece of EMT over the assembly.

The lower supports on the tubes will be standard 1.25" EMT, as this will simplify life. 

 

  • Toe Brakes

The Toe Brakes are actuated by pressing the top of the pedal the forward or down with your toes. On the pedal is the brake arm with a rod end. Unfortunately, the lever arm at the base is missing and will have to be printed as well. The brake shaft can be just a threaded rod.

  • Rudder Self Centering

Rudder Self Centering will be accomplished via two air cylinders. Piping is Front to Front and Back to Back, with springs on the shafts to help in Rudder centering.

  • Toe Brakes

Toe Brakes will use small dampers from the automotive world. This should give the required resistance.