Two Geeks and a Nosegear Modification

[AlexPeterson]

So, despite (or probably in spite of) all the warnings by those who have fought the nose gear rethreading, Pete H. and I tackled gear leg 1 of 2 today.

See, Pete and I are defective. A bunch of credible people say something is difficult, so we sign up.

First, I mount a 94 pound vise (really) to a 12 foot workbench in the hangar. We start along on the threading, and soon realize that the torque needed simply spins the workbench. Time for plan B. We look around the hangar, and amazingly find an old Army tug. This little tug weighs about 2 tons, and has a nice steel plate over the engine. A couple holes later, and we have a vise equipped tug. Let's see if that will spin around...

The real mystery is how the devil that die can take the torque we applied. Our basic strategy was to advance about a half turn, then back off about a quarter. We tried a number of methods, but that seemed to work the least lousily. With two of us reefing on the Swenson bars (probably have to be from Minnesota to understand this), we show that die who is boss. Pete's dog is trying to cover his ears from the groaning - from the die. Back to the torque - we are each pulling about 100 pounds at a 4 foot radius - 800 ft-lbs. Man, that is one good die (made in Canada, cost about $130 from a local supplier)

Anyway, we won round one (still have Pete's plane to do).

It does appear that temperature tightens the die against the gear, so waiting in between cuts seems to help.

Here is Pete manning the initial die holder handles:


Here is after putting on the persuader bars:


This image shows a little lubricant of another sort:

[n5lp]

Originally Posted by AlexPeterson

...See, Pete and I are defective. A bunch of credible people say something is difficult, so we sign up...

Ahh, the experimental spirit is still alive.

[zav6a]

Just watched Mr. Woodcock and this beats it!

[petehowell]

Good thing the it was too cold for the FAA to be out or we might have been slapped with a TWI - Threading while intoxicated....

Yes, this was a bit of fun. As Alex said, the Canadian die is quite amazing.

Mine is next, we'll give our arms and backs a week or so to heal.

[TravisHamblen]

Originally Posted by AlexPeterson

Anyway, we won round one (still have Pete's plane to do).

You guys are so crazy!! But they say its always good to know a couple crazy people. They also say they are the best to have a couple drinks with...

I missed the SB by a couple weeks... otherwise, knowing where your hangar is I might have just left the gear and a couple cases of beer for your attention.

[Geico266]

Good job men!

Can we call this caper two men with a vise?

[zkvii]

Hi,

I'll chime in here, we went the DIY route for cutting / modding the leg - it can be done for ney-sayers. The key here is it depends on how much you value your time, how patient you are, and what the alternatives are.

We ended up getting brand new dies, removed the old fork, cut the extra thread on the leg - in situ, then chopped off and drilled for the cotter pin. Now that makes it sounds 'easy' - it isn't easy, but it is fairly simple.

The biggest challenge is getting smooth even pressure for each of the new '60 degrees' before backing off at least 1 turn each time to really clear the chips. We started with a high grade cutting oil, but found it was "boilling" off too quickly. In the end some generous #22 aeroshell worked well and it really helped with the heat, whilst keeping the chips out / suspended. It took best part of two afternoons (10 hours ish) for the dia cutting work, HEAT being the major factor. Every 1 turn of new thread, die backed right off and cleaned, left to cool - 10+ mins, then another 1 turn in 6 bites..... repeat.

The summary is - if you are prepared to be patient it can be done. But this is the key that many don't 'get' :- IF shipping is sensible, get Harmon to do it by all means - but think of some us - it would have cost > US$300 EACH WAY for shipping, plus $100 modification - that is a $700 job and probably 5 - 7 weeks without a nose leg. We landed the die and holder for less than US$100, 8 hours of (physical) time and we are good to go.

Just another data point,

Carl

[Janekom]

Looks like hard work, but fun. The bottom line is that they will never forget this day and all the sweat!
Carl - same here in South Africa. But instead of sourcing a die, we went to a guy not far from me who has now done about 6 RV legs for about 50 US Dollar a piece on his NC machine. We have ordered and received new forks as well.

[FrankK90989]

I love these stories ----REAL homebuilding!

[N200PF]

Good work guys! ...and thanks for NOT CALLING ME TO HELP!!! Have you figured out why I don't visit your hangar anymore?!?

- Peter

PS - Pete good strategy trying it on Alex's plane first!