General Information:

STEP:

Download a printable version of the build guide here using the link button if required.

STEP:

Nick has an online spreadsheet of parts and cost available at the link Button.

STEP:

The updated MTU decals in DXF form can be downloaded using the Link Button

STEP:

The updated MTU decals in PDF form for desktop printing can be downloaded using the Link Button

STEP:

Using two 24/26AWG cables, Solder to the legs of the Push-button. Use different coloured wires if necessary to help identify the ground and output cables. The ground wire needs to be approx. 100mm in length, Output cable needs to be at least 500mm in length. Create two of these wired buttons per throttle. (4 in total)

STEP:

Insert the cables from a push button into the throttle knob. Feed the cables through the lower hole, Not the centre one used for the attaching screw.

STEP:

Pull the cables through the lower orrifice and gentley pull the push button into position inside the knob.

STEP:

Adjust the push button attaching nut up or down to make the black push button flush with the end of the knob. Once satisfied with the correct height, pull the button back out a little. Use hot glue in the knob to secure the back of the push button in its correct position.

STEP:

With the second push button, Place that into the spacer body. Insert the attachment nut into the external nut orifice, and screw the push button into position from the back, turning the push-button body and not the nut.

STEP:

With a 2mm OD steel rod, cut an angle on one end with a pair of cutters. Insert the 2mm rod into a drill. Insert the angled rod end into the spacer assembly while rotating the drill at speed. This should help to clear the passage way out. Move the rod up and down the passage while its rotating to create the clearance required. This rod needs to move very easily without restriction.

STEP:

Place a 604 bearing into the detent orifice

STEP:

Push the bearing upwards in the channel

STEP:

Squeeze the 6mm OD spring and push it into the orifice. Allow the spring to extend into the hole in the spacer and push against the bottom of the bearing.

STEP:

Place the detent cap into position and secure with a M4 x 6mm countersunk screw

STEP:

Place the Thrust reverser lever onto the spacer body and secure with a M5 x 12mm countersunk screw. Make sure the screw is tight enough that there is no excessive play, and not to tight that operation of the lever becomes too rigid/stiff.

STEP:

Turn the unit over. Ideally, I would highly recommend 3d printing the throttle stem. Then using this as a template to create the hole locations in the Aluminium bar. This bar has a thickness of 3mm x 20mm. Ensure the head of the screw is flush or below the surface. Use the 3d printed part to ensure the aluminium bar is the correct length. Secure with an M4 x 10mm screw

STEP:

I would also 3d print the actuating link. Use this as a template to create the part on a 3mm x 15mm aluminium bar. Secure the bar to the thrust reverser lever with a M5 x 10mm countersunk screw. Again ensure operation is not too stiff by overtightening the screw.

STEP:

Place the throttle knob on the end of the space body, guide the wires into the channel

STEP:

Use Qty 3, M4 x 12mm countersunk screws in these locations to secure the backplate to the spacer body. Ensure you dont trap any cables.

STEP:

Use a M4 x 20mm countersunk screw in this location to secure the backplate and stem.

STEP:

Use a M5 x 22mm screw to attach the throttle knob to the unit.

STEP:

Insert the M5 x 16mm countersunk screw into the reverser knob

STEP:

Attach the Top Plate to the unit with Qty 5, M4 x 10mm countersunk screws.

STEP:

Place two 608 bearings onto the upper mounting lugs. Secure with an M4 penny washer and M4 x 6mm Dome head screw

STEP:

Place a 608 bearing into the centre orifice, press into position, ensure no support material remains.

STEP:

Turn the unit over, place a 608 bearing into the centre orifice to complete the rotational axis.

STEP:

Place a 10K pot with a serrated shaft, into the stem assy. Ensure the locating spigot sits in the designed hole and the unit sits flush.

STEP:

Insert a 604 bearing into the bearing runner, ensure the thick part of the tongue faces down. Secure with a M4 x 10mm dome head screw.

STEP:

Insert a 7.2mm compression spring into the recess. Hold the spring in location.

STEP:

Place the bearing runner into position on the stem assy, feeding the other end of the spring into the locating recess. If you want a stronger detent feel, a second 5mm OD spring can be added inside the 7.2mm spring to increase detent tension. Secure with an M4x 16mm Dome Head Screw.

STEP:

Insert the Rev Spur Gear into the unit as shown and secure with an M4 x 18mm Button Head Screw. depress the bearing runner assy to aid fitment and to check for ease of movement. Ensure the screw is free to rotate in the spur gear without any friction. If needed use a 4.2/4.3mm drill bit to ensure correct tolerances.

STEP:

Push the 8 Tooth Spur gear on the Rev pot. Ensure the pot has full and free movement in both directions of travel. The internal section of the spur gear is splined to match the teeth of the pot. If the Pot is not centred right, you may restrict travel when the pot reaches its endpoints.

STEP:

Put the stem assy to one side, cut a 2mm rod to length (approx 158mm) try to create a rounded end on one end with a file

STEP:

On the other end of the rod, create a 2mm thread that extends approx 20mm from the end.

STEP:

Turn the stem assy over and insert the Rev actuator Button. Compress a 5mm OD spring and insert that behind the plunger part as shown.

STEP:

Insert the Bellcrank and secure it in place with an M4 x 6mm Button head screw. Ensure this unit is free to rotate with any restriction.

STEP:

Insert an M3 x 6mm button head screw. Do not tighten to the point of restriction of movement.

STEP:

Insert the Road Adapter so the round side is down. Line up the holes and insert an M3 x 8mm Dome Head Screw.

STEP:

Inser tthe Lock cap and secure with Qty 3, M3 x 8mm Screws

STEP:

insert the 2mm rod through the stem upper hole, and screw the rod approx 4mm into the rod adapter.

STEP:

If the operating mechanism gets stuck or feels stiff, a 7.5 X 15 mm extra spring can be used and inserted into the spring cutout in the stem below the rod. (All the springs used can be found in an Amazon assorted spring box)

STEP:

Temporarily place the throttle handle onto the stem, feed the wires and rod into the units. use one M4 x 12mm dome head screw to hold the unit in place

STEP:

Ensure the 2mm rod extends into the thrust reverser lever locking the unit. Press the red button and the rod should retract and the lever can then be extended. Adust the length of the rod by screwing it into the rod adapter until the mechanism works correctly.

STEP:

Once happy with the operation, secure the throttle handle to the stem with two, M4 x 12mm dome head screws.

STEP:

Secure the lower Link rod with an M4 x 10mm Dome head screw.

STEP:

Repeat Steps 1-41 for the #2 Throttle Assy

STEP:

Optional, Insert the Pre bought LED light or the newly created unit from PB1 & PB2 (L33 & L34)

STEP:

Place L1 (Throttle Guide #1) onto C1 (LHS Body). Align the screw holes.

STEP:

Insert Qty 3, M4 x 10mm countersunk screws.

STEP:

Place L2 (start Guide #1) into position and secure with Qty 2, M4 x 10mm countersunk screws

STEP:

Place the microswitch into position and Secure it with an M3 x 14mm Socket head screw In the upper corner. Make sure the microswitch is free to rotate along the lower banana slot

STEP:

Place an M3 x 20mm countersunk screw through the lower banana slot and lower corner of the microswitch

STEP:

Ensure the black roller of the arm protrudes into the pie-shaped cutout as shown, Tighten both screws. This can be adjusted later on for fine tuning.

STEP:

Place L3 (Reverse Lock) below the forward edge of L1.

STEP:

Secure with Qty 2, M4 x 12mm Screws. These screws must be flush or below the surface.

STEP:

Insert the L4 (Speed Brake Guide) into C1

STEP:

Secure with Qty 3, M4 x 12mm countersunk screws

STEP:

Place L5 (speed Brake Guide) onto the outer rim and secure with Qty 3, M4 x 8mm countersunk screws.

STEP:

Place the Nema 17 stepper motor into L6 (sliding mount) and secure it with QTY 4, M3 x 6mm countersunk screws.

STEP:

Place the L7 spur gear 8T onto the end of the shaft. This should be a tight friction fit. If the unit is too loose, shrink the component slightly and reprint.

STEP:

Insert Qty 2, M4 x 40mm socket head screws into the L8 clamp Assy.

STEP:

Place the Motor assembly on the LHS body as shown

STEP:

Place the L8 clamp over the stepper assembly.

STEP:

Secure the clamp with Qty4, M4 x 10mm countersunk screws

STEP:

Place the hall sensor into the L9 sliding plate. Secure with Qty 2, M2 x 8mm countersunk screws.

STEP:

Place L10 over the L9 slide plate, Insert the M4 x 25mm tension screw into the side.

STEP:

From the other side, secure the L10 clamp plate with Qty 3, M4 x 10mm countersunk screws

STEP:

Place L11 spur gear onto the shaft, secure with an M3 x 6mm grub screw.

STEP:

Place another Nema 17 stepper motor as shown, and secure with Qty 4, M3 x 8mm countersunk screws

STEP:

Place L12 Spur gear 8TL onto the stepper shaft, this should be a tight friction fit.

STEP:

Using the mounting plate supplied with the hall sensor, Secure the sensor with Qty 2, M3 x 6mm Dome head screws.

STEP:

Place the L13 Spur Gear 9T onto the hall shaft.

STEP:

Insert a 6202 bearing into L14 Spur Gear 44T

STEP:

Place the L14 assembly into position.

STEP:

Insert an M8 x 35mm Bolt with washer into the body to secure L14.

STEP:

Secure with an M8 Nut and washer

STEP:

Insert Qty 2, 608 bearings onto the speed brake stem studs (L15). Secure with two, M4 x 5mm dome head screws and two washers.

STEP:

Place a 6002 bearing into the centre hole.

STEP:

Place another 6002 bearing into the stem on the back side.

STEP:

Place a 684 bearing into the stem orifice.

STEP:

Insert a 5mm x 15mm compression spring into the orifice

STEP:

Use L16 stem template to shape and bend the 3mm x 15mm aluminium bar to an exact copy. Secure the bar with Qty 2, M4 x 10mm countersunk screws.

STEP:

Use Qty 2, M4 x 10mm screws to secure L15 to L16. Ensure the spring is compressed (located into the orifice) and not trapped between the lever and stem body.

STEP:

Place the L17 upper-speed brake arm on the stem assembly and secure it with an M4 x 12mm countersunk screw.

STEP:

Place L18 Speed brake Handle on the upper arm and secure with Qty 2, M4 x 10mm countersunk screws.

STEP:

Insert Qty4, 684 bearings into the L19 Link assy. You may need to apply glue to secure the bearings.

STEP:

Secure the link with an M4 x 16mm dome head screw

STEP:

Insert an M4 x 16mm dome head screw into the lower link bearings. At this point, you NEED to connect the hall sensor to a computer via an interface card such as a Leo Bodnar. Set the handle to the mid position and then ensure the Sensor is mid position. Secure in place. You do not want to build the whole unit to have to take it apart to align the sensors!

STEP:

Insert a 688 bearing into the L20 Start stem.

STEP:

Turn the unit over and insert another 688 bearing.

STEP:

Insert an M4 x 14mm Socket head screw through the 7.9mm expansion spring hoop. Secure in the stem

STEP:

Use L21 Start stem template to create an aluminium replica in 3mm x 10mm bar. Secure the L22 Start Handle with Qty2, M3 x 12mm countersunk screws.

STEP:

Insert an M4 x 5mm socket head screw into the start lever L21.

STEP:

Place the start lever assy L21 into the stem L20 as shown.

STEP:

Secure the L21 lever into the stem through the spring with an M4 x 14mm socket head screw.

STEP:

Turn the unit over, and place another 7.9mm spring onto the screw threads that protrude through the unit.

STEP:

Place start lever into position.

STEP:

Place the #1 throttle assembly on top of the start lever assembly.

STEP:

Insert an M8 x 80mm Bolt

STEP:

Turn the unit over and s ecure the bolt with a washer and M8 lock nut. Do not overtighten.

STEP:

Adjust the tension of the hall sensor to the throttle spur gear by adjusting the tension on the socket head screw. At this point, you NEED to connect the hall sensor to a computer via an interface card such as a Leo Bodnar. Set the handle to the mid position and then ensure the Sensor is mid position. Secure in place. You do not want to build the whole unit to have to take it apart to align the sensors!

STEP:

Adjust the tension of the throttle drive plate through the maintenance hole on the LHS body case.

STEP:

Use 12v white or warm white led strips in the speed brake decal recess.

STEP:

Place the Speed brake decal L23 onto the unit and secure it with Qty 3, M4 x 8mm Dome head screws.

STEP:

Insert C2 centre body on the LHS body C1.

STEP:

Secure the C2 centre assembly to the LHS body with Qty 7, M4 x 25mm countersunk screws.

STEP:

Insert 12v LED strips into L24 SPD BRK Case

STEP:

Place the L25 Trim Decal onto the L24 Spd Case. Secure with Qty 2, M4 x 8mm Dome Head Screws.

STEP:

Secure with Qty 4, M4 x 10mm countersunk screws.

STEP:

Use a further Qty 2, M4 x 10mm Countersunk screws at this location.

STEP:

Place the L25 Speed Brake Block with Qty 2, M4 x 20mm Dome head screws.

STEP:

Place a 684 onto the Bearing detent lever L26) Secure with an M4 x 10mm Dome head screw

STEP:

Place a 5mm x 15mm spring on the other end of the lever.

STEP:

Place the L26 Detent lever on L27 Park Brk Case. Secure with an M4 x 10mm dome head screw.

STEP:

Install the ultra-mini microswitch with Qty 2, M2 x 10mm dome head screws.

STEP:

Place the parking brake lever L28 on the base.

STEP:

Place Qty3, 604 bearings onto the base.

STEP:

Install the Park Brake Cap L29 on top of the bearings. Secure with Qty 3, M4 x 10mm countersunk screws.

STEP:

Place the servo into L30 Servo Mount. Secure with M4 x 6mm screws dome head screws.

STEP:

Place a standard servo arm to the servo and secure with the supplied screw.

STEP:

Install a 604 bearing in the arm. Secure with an M4 x 10mm dome head screw

STEP:

Attach the L32 Link to the Arm L31 with an M2 x 10mm dome head screw.

STEP:

Place the arm assembly onto the base and secure it with an M4 x 20mm dome head screw.

STEP:

Place the servo on top of the Park brake assembly. Attach the Link L32 with an M2 x 10mm dome head screw.

STEP:

Place the park brake unit into the LHS body. Ensure the brake lever arm sits between the locating spigots. Secure the lever with an M4 x 20mm dome head screw.

STEP:

Secure the park brake assembly with Qty 3, M4 x 10mm countersunk screws

STEP:

Use two further M4 x 10mm countersunk screws on the side.