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Rudder Failure on my Xtra.
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yellowbird1



Joined: 01 Nov 2012
Posts: 88

PostPosted: Sun Aug 31, 2014 2:19 pm    Post subject: Rudder Failure on my Xtra. Reply with quote

Kolbers,
The good news is that no one was ingured and the aircraft damage was relatively minor. It could have been a lot worse if it happened in the air.
Recently we had a taxi test in my Xtra with a once around the pattern and shortly after landing the right rudder failed! Atfter a sharp left turn to exit off the runway, without the benefit of a taxiway, the Xtra ending up off the runway with both axels sheered off at the wheel and a bent right wing tip.
After getting the plane back to the hanger I found that the rudder failure was caused by the weld failing between the upright square bar that connects the rudder to the cables. I also noticed that the axel is hollow. Should the axel be solid?
Have any of the Kolbers experienced this before and if so, any suggestions as to the cause of the failure and the best course of action, repair or replace the failed part?
I have attached the photos of the failed part and the sheered axel.
Brad Nation
MK III Xtra
[img]cid:09A6A75C-863B-49A9-9F0D-1B415299FCDF(at)home.network[/img]

[img]cid:1967EC0B-118F-44CE-93C9-8FB1326113CC(at)home.network[/img]
[img]cid:B071CC03-B143-4A02-8895-FBA574E18573(at)home.network[/img]


[img]cid:E6DE017F-4284-4CCF-A700-DDC7BD3E70D0(at)home.network[/img]


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MK3 Xtra
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PostPosted: Sun Aug 31, 2014 6:47 pm    Post subject: Rudder Failure on my Xtra. Reply with quote

The kolb list is very valuable in spreading the word if there is an issue.
Thanks for reporting it.

I think the issue might be that the rudder control system wasn't designed
to handle the load that toe brakes put on the rudder control system. Flight
loads and ground control steering just doesn't put that much load on it.
Like so many things when a seemingly small change is made it can effect a
bunch of other things. Those of us that have the old heal brakes shouldn't
have a issue. For those that have toe brakes check for stress in the area
described. Also check the rudder control horn on the rudder and the rudder
hinges. It would seem that some beefing up of the rudder system is in order
when using the newer toe brake setup. Seems like there was one toe brake
installation that increased the leverage to the master cylinders for this
very reason. Maybe both areas need to be looked at. In the mean time don't
stand on those toe brakes.

As always worth what you paid for it and refunds anytime.

Rick Neilsen
Redrive VW Powered MKIIIC
On Sun, Aug 31, 2014 at 8:47 PM, John Hauck <jhauck(at)elmore.rr.com> wrote:

[quote] Not rudder failure, but what looks like a rudder crank that failed, not
because the weld failed, but the round tube wall stressed cracked over time
and failed. I had a similar aileron crank failure on a Ultrastar in 1985


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PostPosted: Mon Sep 01, 2014 7:57 am    Post subject: Rudder Failure on my Xtra. Reply with quote

Brad/All

The both axles failing at the same time got me thinking. I see dual Matco brake calipers (one may be a bigger caliper) along with the failed rudder controls. I would bet that the brakes were slammed on extremely hard sheering off the axles and braking the rudder system. Not sure what to say. It looks like the brakes were instantly locked up putting way too much torque on the axles. What landing gear legs did you have?  I would guess a nose over could have occurred if things hadn't failed.


 I have the original Kolb optional solid tapered spring steel gear legs. Not sure how they would handle that much braking force.
Again worth what you paid and refunds anytime.


Rick Neilsen
Redrive VW Powered MKIIIC

On Sun, Aug 31, 2014 at 6:19 PM, Brad Nation <nationcap(at)comcast.net (nationcap(at)comcast.net)> wrote:
Quote:
Kolbers,
The good news is that no one was ingured and the aircraft damage was relatively minor. It could have been a lot worse if it happened in the air.


Recently we had a taxi test in my Xtra with a once around the pattern and shortly after landing the right rudder failed!  Atfter a sharp left turn to exit off the runway, without the benefit of a taxiway, the Xtra ending up off the runway with both axels sheered off at the wheel and a bent right wing tip.


After getting the plane back to the hanger I found that the rudder failure was caused by the weld failing between the upright square bar that connects the rudder to the cables. I also noticed that the axel is hollow.  Should the axel be solid?


Have any of the Kolbers experienced this before and if so, any suggestions as to the cause of the failure and the best course of action, repair or replace the failed part?
I have attached the photos of the failed part and the sheered axel.


Brad Nation
MK III Xtra
[img]cid:09A6A75C-863B-49A9-9F0D-1B415299FCDF(at)home.network[/img]

[img]cid:1967EC0B-118F-44CE-93C9-8FB1326113CC(at)home.network[/img]
[img]cid:B071CC03-B143-4A02-8895-FBA574E18573(at)home.network[/img]


[img]cid:E6DE017F-4284-4CCF-A700-DDC7BD3E70D0(at)home.network[/img]



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yellowbird1



Joined: 01 Nov 2012
Posts: 88

PostPosted: Mon Sep 01, 2014 1:25 pm    Post subject: Rudder Failure on my Xtra. Reply with quote

The rudder control failed first causing the hard left turn and running into the soft dirt embankment which caused the wheels to sheer off. The gear legs are tapered steel. The gear legs were buried in the dirt about 4 - 5 inches. Most of the time around here the dirt would have been as hard a concrete, but we have had a very wet rainy season, and would most likely just ridden up the embankment and not into it.
The reason for the dual breaks is that the single ones were not providing enough break pressure. I wasn’t able to hold the plane while doing a run up. I could have replaced the masters or added another set of pads, I opted for the extra pads.

On Sep 1, 2014, at 9:56 , Rick Neilsen <neilsenrm(at)gmail.com (neilsenrm(at)gmail.com)> wrote:
[quote]Brad/All

The both axles failing at the same time got me thinking. I see dual Matco brake calipers (one may be a bigger caliper) along with the failed rudder controls. I would bet that the brakes were slammed on extremely hard sheering off the axles and braking the rudder system. Not sure what to say. It looks like the brakes were instantly locked up putting way too much torque on the axles. What landing gear legs did you have? I would guess a nose over could have occurred if things hadn't failed.


I have the original Kolb optional solid tapered spring steel gear legs. Not sure how they would handle that much braking force.
Again worth what you paid and refunds anytime.


Rick Neilsen
Redrive VW Powered MKIIIC

On Sun, Aug 31, 2014 at 6:19 PM, Brad Nation <nationcap(at)comcast.net (nationcap(at)comcast.net)> wrote:
Quote:
Kolbers,
The good news is that no one was ingured and the aircraft damage was relatively minor. It could have been a lot worse if it happened in the air.


Recently we had a taxi test in my Xtra with a once around the pattern and shortly after landing the right rudder failed! Atfter a sharp left turn to exit off the runway, without the benefit of a taxiway, the Xtra ending up off the runway with both axels sheered off at the wheel and a bent right wing tip.


After getting the plane back to the hanger I found that the rudder failure was caused by the weld failing between the upright square bar that connects the rudder to the cables. I also noticed that the axel is hollow. Should the axel be solid?


Have any of the Kolbers experienced this before and if so, any suggestions as to the cause of the failure and the best course of action, repair or replace the failed part?
I have attached the photos of the failed part and the sheered axel.


Brad Nation
MK III Xtra
<IMG_0971.jpg>

<Rudder failure close up.jpeg>
<IMG_0973.jpg>


<IMG_0993.jpg>




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Dennis Kirby



Joined: 05 Dec 2013
Posts: 35
Location: Albuquerque, NM

PostPosted: Wed Sep 03, 2014 1:23 pm    Post subject: Rudder Failure on my Xtra. Reply with quote

J.Hauck wrote:
<< Not rudder failure, but what looks like a rudder crank that failed, not because the weld failed, but the round tube wall stressed cracked over time and failed. I had a similar aileron crank failure on a Ultrastar in 1985. Weld was good but the rotating tube wall stress cracked and failed. First I have heard of this type failure in a rudder crank. >>

Kolbers -

Hauck is correct: It was the torque tube on the rudder pedal assembly that failed on Brad's Xtra ... not the weld. Failure was likely due to accumulated stress on the part. This Kolb aircraft has 240 hours of time on it.

What concerns me is, this was a critical, safety-of-flight component that failed. Good thing this happened on a landing rollout, and not in flight. Why did this steel part fail? Is anybody else who flies the Mark-III Xtra concerned that this same part might fail on YOUR aircraft? No amount of rudder pedal pressure exerted by a person in the cockpit should cause this part to break. Otherwise, the part is not designed strong enough.

Rick Neilsen suggested that the extra stress from the pedal-mounted toe brakes may have contributed to the failure. OK, but that is still a Kolb-provided option - not some homebuilder's one-off modification. The part should be built to take that kind of stress.

Seems to me that Kolb should be making this part from thicker-walled steel tubing. I hope the Kolb factory doesn't wait until another failure of this kind happens - with a possible horrible aftermath - before they decide to improve the design of that part.

Sorry for the rant here, but the somewhat lukewarm response from our Kolb community to this alarming failure has motivated me want to ask these questions. I guess you could say my confidence in the Kolb design is a little bit shaken after seeing this. Should we worry about any of the OTHER welded steel parts that we trust will remain intact to fly our Kolbs safely?

Dennis Kirby
Mark-III (Classic)
Flying it for 12 years
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Jason Omelchuck



Joined: 07 May 2009
Posts: 120
Location: Portland Oregon

PostPosted: Thu Sep 04, 2014 7:55 am    Post subject: Re: Rudder Failure on my Xtra. Reply with quote

I agree, it is disconcerting to have a flight critical part fail. Please remember you are flying an experimental aircraft. It is built with non aircraft (approved) parts and not designed and built to approved aircraft standards. Even when planes are built with approved parts they fail. I would use this as a wake up call to inspect every piece of steel on your aircraft for cracks. I would mention this desire to the next person who annuals the aircraft. It is good you have posted this on the list so others can immediately go inspect their aircraft. Use this as an opportunity to adjust your perspective and make yourself safer.

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John Hauck



Joined: 09 Jan 2006
Posts: 4639
Location: Titus, Alabama (hauck's holler)

PostPosted: Thu Sep 04, 2014 10:21 am    Post subject: Rudder Failure on my Xtra. Reply with quote

Jason O/Kolbers:

The reason I bought my first Kolb aircraft kit, an Ultrastar, February 1984,
was because it was delivered with, primarily, aviation parts and material.
Even then, I had an aileron bell crank fail like the MKIIIx rudder bell
crank. Pulled the crank right out of the tube wall, weld and all. As far
as I know, I am the only one that achieved that mark of distinction. There
may have been others, but Homer Kolb kept it a secret if there was.

Kolb aircraft are built with standard aviation parts and material,
especially in flight critical areas. There are non-standard items on Kolb
aircraft, but most all of them are not used in flight critical systems.

I got a feeling our friend has a strong leg and a strong arm on the
controls. Took some work to weaken the rudder pedal bell crank and axles,
to the point they failed his last landing. I may have the heaviest MKIII in
the inventory, and probably fly with heavier loads than most. I used those
same axles and wheels for more than two thousand hours and thousands of
landings. Never broke an axle but broke the weld/tube wall from the gear
leg/axle socket. I have a feeling if I had kept on accumulating hours and
landings on those 5/8" axles, they would have failed too.

Personally, and my opinion only, the failure of a rudder pedal or bell crank
is not flight critical on a Kolb. If you were club footed enough to break
one in the air, you can fly and land the Kolb without killing yourself.
Here's where it is nice to have good differential braking, that works. Very
easy to maintain and control yaw, and steer the Kolb on the ground with
differential brakes. Because I have around 100 lbs on my tail wheel, I
depend on differential brakes most of the time to help me control my MKIII
on the ground.

Kolbs are experimental to a point. For the most part, Hauck's opinion
again, that doesn't mean much except the aircraft may have been amateur
built and has not been certified. I have an FAA Airworthiness Certificate
issued for N101AB. That's good enough for me. I like to think Homer Kolb's
airplanes have been tested with thousands and thousands of flight hours over
the past 30 plus years. Like Jason said, there are parts that wear out and
break on certified aircraft. When something like that happens to our Kolbs,
this is a good place to share so we can all make note of it and take
necessary action to fix it.

john h
mkIII
Titus, Alabama




I agree, it is disconcerting to have a flight critical part fail. Please
remember you are flying an experimental aircraft. It is built with non
aircraft (approved) parts and not designed and built to approved aircraft
standards. Even when planes are built with approved parts they fail


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rickofudall



Joined: 19 Sep 2009
Posts: 1392
Location: Udall, KS, USA

PostPosted: Thu Sep 04, 2014 2:17 pm    Post subject: Rudder Failure on my Xtra. Reply with quote

Jason, The 4130 seamless steel tubing used in a Kolb IS aircraft quality, so are the aluminum alloys that make up the spars, ribs and control surfaces, the AN bolts that hold parts together and the cloth that covers it all. Please take the time to think before you post such nonsense. Now about the break. The best thing to do is have the part analyzed to see what caused the break. Too much heat used during the welding process? Allowing the weld to cool too fast? There are a number of causes that a metallurgical lab would be able to pinpoint, Then we could all make a reasoned decision about what steps to take AFTER we know the TRUE cause. What we don't need is incoherent raving.
My 2 cents. Carry on.
Rick Girard
do not archive

On Thu, Sep 4, 2014 at 10:56 AM, Jason Omelchuck <jason(at)trek-tech.com (jason(at)trek-tech.com)> wrote:
Quote:
--> Kolb-List message posted by: "Jason Omelchuck" <jason(at)trek-tech.com (jason(at)trek-tech.com)>

I agree, it is disconcerting to have a flight critical part fail.  Please remember you are flying an experimental aircraft.  It is built with non aircraft (approved) parts and not designed and built to approved aircraft standards.  Even when planes are built with approved parts they fail. I would  use this as a wake up call to inspect every piece of steel on your aircraft for cracks.  I would mention this desire to the next person who annuals the aircraft.  It is good you have posted this on the list so others can immediately go inspect their aircraft.  Use this as an opportunity to adjust your perspective and make yourself safer.




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Zulu Delta
Mk IIIC
Thanks, Homer GBYM
It isn't necessary to have relatives in Kansas City in order to be unhappy.
  - Groucho Marx

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rickofudall



Joined: 19 Sep 2009
Posts: 1392
Location: Udall, KS, USA

PostPosted: Thu Sep 04, 2014 2:36 pm    Post subject: Rudder Failure on my Xtra. Reply with quote

As long as I'm thinking about it, here's a simple thing Brad could do that would help start the investigation. Pull out the part that broke off and look at the nature of the break. Is there a part that shows signs of corrosion, i.e. rust? This would most likely be where the crack started. Is there a portion that appears as though the weld did not penetrate both sides of the weld line? Is there a portion of the crack that appears polished? This would indicate that after the crack started the two parts worked against each other as the crack grew. How much of the material appears grainy? This would be the area that finally gave up when the last stress was applied and the part finally failed. >From this visual analysis reasonable ideas about whether the failure was caused by a manufacturing defect, a design defect, or a material defect.
Anyway, that's where I'd start if it were my rudder pedal weldment.
Again, my 2 cents, or is that 3?
Rick Girard
do not archive

On Thu, Sep 4, 2014 at 5:16 PM, Richard Girard <aslsa.rng(at)gmail.com (aslsa.rng(at)gmail.com)> wrote:
Quote:
Jason, The 4130 seamless steel tubing used in a Kolb IS aircraft quality, so are the aluminum alloys that make up the spars, ribs and control surfaces, the AN bolts that hold parts together and the cloth that covers it all. Please take the time to think before you post such nonsense. Now about the break. The best thing to do is have the part analyzed to see what caused the break. Too much heat used during the welding process? Allowing the weld to cool too fast? There are a number of causes that a metallurgical lab would be able to pinpoint, Then we could all make a reasoned decision about what steps to take AFTER we know the TRUE cause. What we don't need is incoherent raving.
My 2 cents. Carry on.
Rick Girard
do not archive

On Thu, Sep 4, 2014 at 10:56 AM, Jason Omelchuck <jason(at)trek-tech.com (jason(at)trek-tech.com)> wrote:
Quote:
--> Kolb-List message posted by: "Jason Omelchuck" <jason(at)trek-tech.com (jason(at)trek-tech.com)>

I agree, it is disconcerting to have a flight critical part fail.  Please remember you are flying an experimental aircraft.  It is built with non aircraft (approved) parts and not designed and built to approved aircraft standards.  Even when planes are built with approved parts they fail. I would  use this as a wake up call to inspect every piece of steel on your aircraft for cracks.  I would mention this desire to the next person who annuals the aircraft.  It is good you have posted this on the list so others can immediately go inspect their aircraft.  Use this as an opportunity to adjust your perspective and make yourself safer.




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http://forums.matronics.com/viewtopic.php?p=429973#429973







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--
Zulu Delta
Mk IIIC
Thanks, Homer GBYM
It isn't necessary to have relatives in Kansas City in order to be unhappy.
  - Groucho Marx



--
Zulu Delta
Mk IIIC
Thanks, Homer GBYM
It isn't necessary to have relatives in Kansas City in order to be unhappy.
  - Groucho Marx

[quote][b]


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Jason Omelchuck



Joined: 07 May 2009
Posts: 120
Location: Portland Oregon

PostPosted: Thu Sep 04, 2014 4:02 pm    Post subject: Re: Rudder Failure on my Xtra. Reply with quote

Rick, your MKIII must have been different than mine because mine was not built to any aircraft standard. I did not compare the parts I received to the engineering drawings, I did not even receive dimensional drawings to compare the parts to. Heck I even put a plaque in my that stated it was amateur built and did not comply with FAA standard aircraft rules. Mine was put together with a couple of thousand hardware store stainless steel pop rivets. The poly fiber I used was not FAA/PMA stamped. I think you take my post the wrong way. I like Kolbs and think they are fine aircraft and for me that is not diminished by the fact it does not meet aircraft standards. Some of the parts I used may be the same alloys or manufactured the same way as aircraft parts but that does not make the airplane built to FAA aircraft standards.

FWIW
Jason


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baberdk



Joined: 23 Jan 2014
Posts: 53
Location: East Moline, Il

PostPosted: Fri Sep 05, 2014 6:09 am    Post subject: Rudder Failure on my Xtra. Reply with quote

Has anyone thought about putting springs in series with the rudder cables to prevent overstressing the parts? Sincerely,
Denny Baber

do not archive


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rowedenny



Joined: 09 Mar 2008
Posts: 338
Location: Western PA

PostPosted: Fri Sep 05, 2014 6:30 am    Post subject: Rudder Failure on my Xtra. Reply with quote

Absolutely not! 😬 

Dennis "Skid" RoweMk3, Rotax 670,
Leechburg, PA
On Sep 5, 2014, at 10:09 AM, Denny Baber <baberdk(at)gmail.com (baberdk(at)gmail.com)> wrote:
[quote]Has anyone thought about putting springs in series with the rudder cables to prevent overstressing the parts? Sincerely,
Denny Baber

do not archive


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rickofudall



Joined: 19 Sep 2009
Posts: 1392
Location: Udall, KS, USA

PostPosted: Sat Sep 06, 2014 6:49 am    Post subject: Rudder Failure on my Xtra. Reply with quote

Denny, I don't know which model Kolb you have, but if it's a Mk III the next time you're flying take your feet off the rudder pedals. That's why you want a firm connection between pedals and rudder.

Rick Girard
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On Fri, Sep 5, 2014 at 9:09 AM, Denny Baber <baberdk(at)gmail.com (baberdk(at)gmail.com)> wrote:
Quote:
Has anyone thought about putting springs in series with the rudder cables to prevent overstressing the parts? Sincerely,
Denny Baber

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John Hauck



Joined: 09 Jan 2006
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Location: Titus, Alabama (hauck's holler)

PostPosted: Sat Sep 06, 2014 7:18 am    Post subject: Rudder Failure on my Xtra. Reply with quote

I have tension on my rudder pedals feet on or off.  Kolbs, most of them, suffer from rudder shuffle, which may lead into rudder flutter if ignored, which is easy to do on long cross country flights over boring terrain.  I double spring'd my rudder pedals which eliminates rudder shuffle.  Richard Pike eliminated the problem on his MKIIIc by designing a rudder counter balance weight.

Overstressing the rudder control system is a pilot problem.  Depends on how badly you scare yourself.

I've been around Kolb airplanes for a good while.  First time I have heard of a rudder bell crank failure on a MKIIIx.  The other model Kolbs don't use that system.  I can testify how much abuse rudder pedals can take by relating a few of my accidents and screw ups.  Sudden stops will peg the G meter in forward deceleration.  Imagine what kind of stress that puts on the rudder pedals.

john h
mkIII
Titus, Alabama - Packing my bag and loading my MKIII for an early morning departure in the morning.  All I have to do is get up and get going.



                   [quote] Denny, I don't know which model Kolb you have, but if it's a Mk III the next time you're flying take your feet off the rudder pedals. That's why you want a firm connection between pedals and rudder. Rick Girarddo not archive[b]


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PostPosted: Sat Sep 06, 2014 3:29 pm    Post subject: Rudder Failure on my Xtra. Reply with quote

HEY JOHN
BONG VOYAGE AND HAVE A GREAT FLITE!
WE ALL ENVY YOU
RUSS


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undoctor



Joined: 21 Oct 2008
Posts: 212
Location: Bethelhem, PA

PostPosted: Sat Sep 06, 2014 3:56 pm    Post subject: Rudder Failure on my Xtra. Reply with quote

Ditto that, John. Big time envy!
Dave Kulp
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-------- Original message --------
From: kinne russ
Date:09/06/2014 7:29 PM (GMT-05:00)
To: kolb-list(at)matronics.com
Subject: Re: Kolb-List: Rudder Failure on my Xtra.
--> Kolb-List message posted by: kinne russ <russk50(at)gmail.com>

HEY JOHN
BONG VOYAGE AND HAVE A GREAT FLITE!
WE ALL ENVY YOU
RUSS

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John Hauck



Joined: 09 Jan 2006
Posts: 4639
Location: Titus, Alabama (hauck's holler)

PostPosted: Sat Sep 06, 2014 3:56 pm    Post subject: Rudder Failure on my Xtra. Reply with quote

Wish you all could fly along with me.

john

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lcottrell



Joined: 29 May 2006
Posts: 1494
Location: Jordan Valley, Or

PostPosted: Sat Sep 06, 2014 3:56 pm    Post subject: Rudder Failure on my Xtra. Reply with quote

On Sat, Sep 6, 2014 at 5:29 PM, kinne russ <russk50(at)gmail.com (russk50(at)gmail.com)> wrote:
Quote:
--> Kolb-List message posted by: kinne russ <russk50(at)gmail.com (russk50(at)gmail.com)>

HEY JOHN
BONG VOYAGE AND HAVE A GREAT FLITE!
WE ALL ENVY YOU
RUSS



Yeah, but John doesn't smoke! Smile
Larry 
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yellowbird1



Joined: 01 Nov 2012
Posts: 88

PostPosted: Sat Sep 06, 2014 6:50 pm    Post subject: Rudder Failure on my Xtra. Reply with quote

You think we could stay with the topic of the original post? Just a suggestion Smile


Yellow Bird 1
Brad Nation
MKIII Xtra
N952DK




On Sep 6, 2014, at 17:29 , kinne russ <russk50(at)gmail.com (russk50(at)gmail.com)> wrote:
[quote]--> Kolb-List message posted by: kinne russ <russk50(at)gmail.com (russk50(at)gmail.com)>

HEY JOHN
BONG VOYAGE AND HAVE A GREAT FLITE!
WE ALL ENVY - The Kolb-List --> http://www.matronics========================[b]http://www.matronics.com/co=================

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baberdk



Joined: 23 Jan 2014
Posts: 53
Location: East Moline, Il

PostPosted: Mon Sep 08, 2014 5:08 am    Post subject: Rudder Failure on my Xtra. Reply with quote

I have a Mark III, but I didn't mean to imply to disconnect the rudders. What I meant to say was to put springs in series between the rudders and the pedals that would withstand around two hundred pounds of tension. The only time they would operate would be if you pushed on both pedals and exceeded the springs limits, but before you could damage metal parts. The only time they would operate would be to save the plane from pilot error. I have not tried this, I was wondering if anyone had thought about it and tried it so I wouldn't have to. Sorry for the misunderstanding.

Sincerely,
Denny Baber




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