Take it to someone who builds custom headers and has a 'mandrel' bending
machine. (check speed shops, high performance motorcycle shops, etc.) They
do 'one offs' all the time and it is pretty much time and materials (unless
you bring your own tubing). They might need to get a little creative because
of the smaller overall diameter tube, but it should be doable. 

JMHO

Mark W.
N952MW (res)

-----Original Message-----
From: KRnet [mailto:krnet-bounces at list.krnet.org] On Behalf Of Mark Langford
via KRnet
Sent: Wednesday, September 10, 2014 9:21 PM
To: KRnet
Subject: Re: KR> rudder pedals

Tony King wrote:

> My builders guide shows the rudder pedals as bent tube rather than welded.
> Has anyone built them this way?  What are the pros and cons?

Bent would be stronger than welded, as there would be "no heat affected
zone" to weaken the parent material, as you get from welding.  A CNC bender
would make quick work of this job, but given the scale, it may be difficult
to recoup programming costs without buying a bunch of them.  Somebody in
that business...like nvAero, might just be up to the task.

I used .049" for mine, and have thoroughly abused them on landings by
pushing hard on both pedals out of pure apprehension!  But they have almost
three thousand landings on them, so .049" is sufficient if welded properly. 
See http://www.n56ml.com/pedals/index.html for more on that...

Mark Langford
ML at N56ML.com
website at http://www.N56ML.com
--------------------------------------------------------


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