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Brake.. I am working with a DER to get FAA approval for hyd brake conversion that may benefit a lot of BC12D owners. I am setting up a model to determine the pressures produce using Cleveland Brake cylinders activated by the original pedals.. The question: is he leverage of the original pedals enough to activate the brakes.
Have you considered MAKING new pedals? You could make a couple of simple improvements to the design like increasing the size of he foot pad a bit and making the vertical arm longer below if you are attaching the master there or deeper if you are attaching it behind the pedal. I have done some engineering on control force analysis and would enjoy working some if the engineering if you are interested. I also have a restored fuselage (un covered) with dual factory brakes that aren't in yet. It would be perfect for testing your concepts.
Don't over think this. You can google the forces for using your heels, its something like 200# or more, toe pressure is less than heel pressure. The master vs caliper size is also important, you don't need dual puck brakes on a Taylorcraft, even with 31" wheels. Dual pucks are a good way to flip an airplane on its back.
If it was me, I would mount the master cylinders on the through holes of the gear where the mechanical brake bellcrank is mounted. Use a 3/16" pin and a spacer to take up the slack on the lower mount, use an AN111 cable bushing for the upper part of the master cylinder, run the cable to the pedals, mount the reservoir on the gear leg with a strap or directly to the master via a 1/8" nipple, a short hose to the calipers and done.
Good idea Tim about the lower gear leg pull cylinders (http://www.groveaircraft.com/mcpull.html) and using cable that's already available. How about a fluid feed reservoir on the firewall with split feed lines from a bulkhead fitting on the boot cowl? I'd also want to protect the master's extension rod from debris with a flexible rubber cover like shock absorbers use. Reservoirs often have a drilled 1/8" NPT vent plug that can be exposed to the elements.
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