Carbon fiber brake covers

[kevinbrooker]

Because I have the materials, like doing this stuff, and needed parts, I made up some brake dust covers from carbon fiber. The parts in the photo are test pieces to figure out layups etc. The final parts are in the molds now and should have that sexy carbon look which will go away when they are painted to match the rest of the ship. The white pieces are 3D drilling templates and can index for either the R or L side. As to the legalities of homegrown parts on certificated airplanes question: As I read the regs and after asking several IAs about this, the answer seems to be making non structural parts is okay regardless of materials as long as it will work as originally intended.

Weight wise the CF brake parts weigh 10 grams less per side than the a lauminum originals. Just for grins I calculated replacing all aluminum fairings with CF parts will save about 12 oz. Enough fuel to run the engine for about 5 minutes.

[Robert Lees]

That's impressive work, despite the small weight benefit. Please keep us posted.
A friend of mine saved about 20lb on his Pitts S1 by doing similar CF work to the seat, spats, cowls etc; many hours work).

My comment to him that he should just have gone on a diet and taken a decent sh!t in the morning was not well received.

[kevinbrooker]

I completely agree on the diet and good bowel movement weight loss advice. Every little bit helps! These CF projects are more for my entertainment than anything else. I made up some inspection hole covers too. There is a certain irony about putting modern materials on an old classic airplane. Another attraction is the speed of acquisition of these smaller parts. I can make them with materials on hand faster than having materials shipped. Since the materials were paid for by other projects the parts are "free" if my time isn't accounted for. If we do, the two dust covers are worth more than the rest of the ship. I enjoy working with metal I just don't have the tools and knowledge to make complicated shapes like the dust covers. The mold for them was made on a lathe out of a piece of cherry, sealed, and waxed so the epoxy will release. Figuring out the carbon cloth layup schedule took a few tries and most of the time was waiting for the resin to cure. In the net few years the number of CF parts on my ship will increase just because doing the work is part of the fun of owning the airplane. I'll post pics after the parts are installed.

[kevinbrooker]

Here are the covers installed on the gear legs.

[Robert Lees]

They look great, Kevin! Paint them silver and no-one would know. Owner-produced parts in action.
Don't forget the figure-8 security links between the adjusters and the hubcaps (I see you have the split pin/cotter pin ready to go!)
Rob

[kevinbrooker]

Hi Rob
Thanks for the reminder on the security links. I hadn't yet adjusted the throws when the pictures were taken. I bent up a new set of the security links too. I enjoy making up CF parts and am slowly replacing the bent/cracked/ovalized hole fairings and cover with homegrown pieces. The aircraft empty weight will have save a few grams which is not the motivation. Trying to spend less time watching TV, playing on the internet, problem solving and having a pile of cloth and resin to use up is the driving force.