Chpt 16 - Control System



Cozy Build Project
Engine Options
Pre - Chpt
SAAA - Chapter 24
Project Costs

Working on Chapter 19

updated: 09/05/2022


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Step 1 2 Pivot Mounts, Fabrication of Pitch and Roll Parts

In this chapter you install and rig the Pitch, Roll, and Yaw control systems. I purchased all the recommended parts for Ch 16 and 17 from both Wicks and Cozy Girls, this included the joystick assembly and rear bellhorns.

I decided not to turn the Fuselage onto its side and proceeded to level the Fuselage by extending the Nose wheel until the Longerons were level.  CS109 & CS118 bearing blocks were made as per plans from 1/4" Birch plywood.  There was no need to make the CS108 & CS117 bearings as these have been replaced with the FMN10 bearings sourced from Wicks.

Step 3 Assembly of Pitch and Roll Parts

I pre-assembled the left and right hand side Pitch and Roll Controls on the bench and then measured up and located the positions for permanently fitting the CS109 & CS118 bearings to the sides of the Fuselage.  CS109 is shown on Pg 16-3 as been located at W.L. 9.5 & F.S. 46.25.  The top longeron is located at W.L. 23 and the Instrument Panel is located at F.S. 41.25. 


 So CS109 needs to be 5" from the FWD face of the I.P and 13.5" down from the Top of the Longeron. As my fuselage was not on its side I needed a way of holding the Bearings in place, whilst I did a trial setup.  I found a pair of steel squares and using Super Glue bonded the CS109 bearings at the correct height and clamped these into place under the longerons.  This worked out well and kept the bearings nice and square.  CS118 is shown on Pg 16-3 as been located at W.L. 9.4 & F.S. 80. 


Before test fitting the controls torque tubes, I needed to drill the holes through the Firewall, Aft & Fwd Landing Bulkheads.  From the M-drawings I obtained the location of the 7/8" holes in the Firewall and Fwd Landing gear bulkhead.  I drilled a pilot holes first through all panels taking special care to keep the drill bit level at all times.  I then opened up the 1/4" pilot holes using the 7/8" cutter used in Chpt 9.  I then carefully filed and opened up the firewall holes to accept the Bronze FB1013 bearings.


Step 4 Installation of Pitch and Roll Assembly

I installed the rest of the rear push rods CS121 and CS122 as per plans, Then proceeded to set the Joystick at 5 degrees fwd to allow the length of the elevator pushrods to be determined with the Elevators clamped in the zero position.  From the centre of the hole on the Joystick to the hole in the elevator bracket was 24", so I made CS102 as per plans at 14" long and cut the CS136 tubes to 7.5", allowing 1.25" for each rod end set at mid point( approx. 10 turns out). I used the CozyGirls Quick Connect kit (C6-CS-108-QDK) to join CS102 & CS136 with the supplied rivets.  As my wings and centrespar have not been drilled and fitted to the fuselage yet, I will come back to finishing off the install & setup of the aileron pushrods.


Step 5 Routing and Rigging the Rudder Cables

I fitted the electrical conduits to the fuselage sides first, before running the Nylaflow tubes for the rudder cables as they seem to follow and in some places rest on top of these conduits. I found some 1" x 1 1/8" wooden strips 50" long, covered them in box tape and proceeded to cover them with 1 layer of BID.  After cure I trimmed the sides so that they had a 10mm flange on each side and cut the ends to match where they mated to the rear seat and exit at the firewall.  I used small 3mm screws to hold them in place, whilst the flox cured as well as a wooden jig I made to push these conduits neatly against the fuselage sides.  Overall I was quite happy with the finished installation.



I cut 2 lengths of 3/16" Nylaflow tubing 86"long, sanded them with 100 grit paper along the entire length and then threaded through a 3/16" hole drilled in the IP at W.L.8, along the top of the electrical conduit to F.S.108, and then inside the electrical conduit to the Firewall.  The Nylaflow tube started 2" in front of the IP and finished 1/4" aft of the Firewall.  The Nylaflow tube was then floxed and taped with a single layer of BID every 6" the entire length.  A check was made to ensure that the bottom of the Joystick cleared the tube as shown in view A.A - Pg16-4.


I'm going to leave the threading and fitting of the 2 x 12ft lengths of 1/16 x 7 x 7SS aircraft control cable to the rudder pedals until the Wings and pulleys have been installed.   

Step 6 Rudder Stop and Brakes

I'm going to leave this section and come back to complete this when the Wings have been fitted to the fuselage.



Onto Chapter 17