Rudder Pedal
Modification
Page 1
Although my arms and legs stick out, the original
AirBike cockpit always seemed a bit small.  
When I built my fuselage I raised the wing 1-1/2"
and pushed the seat back 2" but forgot to
consider my 33" inseam length.  Consequently
my knees always were positioned a bit high
which was uncomfortable.
A fellow AirBiker, William Everette of Florida,
mentioned a mod he made to his AirBike which
seemed like the perfect solution. Following his
coaching I did something similar to my plane.  
You may find it interesting and hopefully this
page will help you duplicate the process.
This modification can be made to an AirBike either underconstruction or
during a retrofit.  I have retrofitted my plane in such a manner that the mod
is not permenant, the plane can be returned to it's original condition quickly.
These dimensions allowed me to move the
rudder pedal pivot tube from its original position
to that of being in front of the firewall.
Bending the link accomodated the fuselage
taper, the two tubes accomodated the
existing pivot bracket tube and new pivot
bracket tube.
Wooden link installed for test fit,
permitting pivot tube to be moved
forward.  Note the clamp temporairly
securing the pivot tube.
Being a woodworker, I made the welding jig
from wood.  The angle conforms to the bent link,
the holes accept the two tubing sizes, the round
head screws act as standoffs and the end screws
hold the tubes in position during welding.
All the pieces are in place and ready for welding on
the exposed side.  The C-clamp holds the link in
place.  The countersink on the flush mounted tube
allows room for the weld bead.
The photo at right
shows how the
standoff round head
screws maintain
clearance to avoid
burning the jig during
welding.
Welding the other side is done after
removing the parts from the jig.
Finish welded/painted parts ready for installation.
Small unpainted tubes go inside the existing pivot
bracet tubes,  and painted tubes house the newly
located pivot tube.
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