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Date: Mon, 09 Jun 2014 07:36:37 -0400
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From: John Cooper <snopercod@comporium.net>
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Subject: Re: [LML] [LNC2] MLG tires hitting upper wing skin
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Thanks to Chris, Bill, and Greyhawk for the suggestions. Here's an update:

It proved to be impossible to remove (or reconfigure) shims to move the 
axle closer to the gear casting; Anything I tried caused the brake pads 
to interfere with the disc. Actually, to get the best fit between the 
brake pads and the disc, I had to *_add _*another .062 shim to the .180 
already in place. So now I have a total of .242  (basically, 1/4") of 
shims between the brake mounting plate and the axle. The old Rosenhan 
brake mounting plate was .228 (not .210 as I previously posted). The new 
Matco brake mounting plate is .125, the difference being .103". So the 
axle, wheel, and tire now stick out .242 minus .103 or .138" farther 
than before - a little over 1/8".

Today I compared the old Rosenhan parts to the new Matcos to try and 
figure out what the heck was going on; The only difference I found was 
the thickness of the aluminum brake shoes and the thickness of the brake 
mounting plate. (I haven't measured the standoff bushings yet.) The old 
Rosenhan cast-aluminum shoes were ~1/32" thicker than the new Matcos. 
(Note: I was wrong when I said the new brake pads are thicker; They're 
still the same.) In summary, nothing jumped out at me to account for the 
difference in form and fit.

I've had to withdraw the previous Kudos I awarded to Matco. As we got 
further into this problem, their tech support started just sending me 
copies of drawings which were obviously not valid for installation in 
the Lancair. I sent them photos and actual measurements, but they simply 
ignored all of that and kept sending me the same wrong information. It's 
a shame they wouldn't work with me on this, but I'm clearly on my own now.

My middle gear door is already hogged out to allow the gear casting to 
nest right into it - I removed the core and used micro to make a nice, 
clean mold of the gear casting. After cleaning up the recessed area, I 
then layed 2 bid (?) bid over it. There's no room for further adjustment 
there and, besides, the puck housing and brake hose are in the way of 
further movement. Bending the aluminum bracket might gain me a little 
but, once again, the gear puck housing is the limiting factor; It's 
already smack up against the gear door.

At the moment, I'm leaning toward option 1 - removing some of the wing 
skin core and glassing over the removed area, but there _*is *_an Option 
5: Reinstall the old Rosenhahn brakes. I already cleaned them up and 
replaced the puck O-rings, so they would be perfectly serviceable if I 
replaced the pads.


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    Thanks to Chris, Bill, and Greyhawk for the suggestions. Here's an
    update:<br>
    <br>
    It proved to be impossible to remove (or reconfigure) shims to move
    the axle closer to the gear casting; Anything I tried caused the
    brake pads to interfere with the disc. Actually, to get the best fit
    between the brake pads and the disc, I had to <b><u>add </u></b>another
    .062 shim to the .180 already in place. So now I have a total of
    .242&nbsp; (basically, 1/4") of shims between the brake mounting plate
    and the axle. The old Rosenhan brake mounting plate was .228 (not
    .210 as I previously posted). The new Matco brake mounting plate is
    .125, the difference being .103". So the axle, wheel, and tire now
    stick out .242 minus .103 or .138" farther than before - a little
    over 1/8".<br>
    <br>
    Today I compared the old Rosenhan parts to the new Matcos to try and
    figure out what the heck was going on; The only difference I found
    was the thickness of the aluminum brake shoes and the thickness of
    the brake mounting plate. (I haven't measured the standoff bushings
    yet.) The old Rosenhan cast-aluminum shoes were ~1/32" thicker than
    the new Matcos. (Note: I was wrong when I said the new brake pads
    are thicker; They're still the same.) In summary, nothing jumped out
    at me to account for the difference in form and fit.<br>
    <br>
    I've had to withdraw the previous Kudos I awarded to Matco. As we
    got further into this problem, their tech support started just
    sending me copies of drawings which were obviously not valid for
    installation in the Lancair. I sent them photos and actual
    measurements, but they simply ignored all of that and kept sending
    me the same wrong information. It's a shame they wouldn't work with
    me on this, but I'm clearly on my own now.<br>
    <br>
    My middle gear door is already hogged out to allow the gear casting
    to nest right into it - I removed the core and used micro to make a
    nice, clean mold of the gear casting. After cleaning up the recessed
    area, I then layed 2 bid (?) bid over it. There's no room for
    further adjustment there and, besides, the puck housing and brake
    hose are in the way of further movement. Bending the aluminum
    bracket might gain me a little but, once again, the gear puck
    housing is the limiting factor; It's already smack up against the
    gear door.<br>
    <br>
    At the moment, I'm leaning toward option 1 - removing some of the
    wing skin core and glassing over the removed area, but there <u><b>is
      </b></u>an Option 5: Reinstall the old Rosenhahn brakes. I already
    cleaned them up and replaced the puck O-rings, so they would be
    perfectly serviceable if I replaced the pads.<br>
    <br>
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