Belowdecks, Ignatius breathed out hard to pump a little more power into his helmet's Stirling engine and twisted the zoom control, taking a closer look at one of the shaft linkages in the rudder mechanism. Something sounded wrong when he had fiddled with the controls experimentally, and he wanted a closer look.
"All right, you metallic monstrosity, how have you chosen to ruin my day this time?"
He inspected each linkage carefully, then pulled a small pressure gauge from one of the innumerable pockets on his vest and started checking the hydraulic cylinders. Pressure was fine on the right main, but the left...the left was below optimal.
"So where are you leaking, hmm? Let's have a look at the shaft..."
Sure enough, hidden under the gasket that covered where the shaft went into the cylinder, was the inescapable fact that the manufacturer had made the cylinder a quarter-inch too wide, and the shaft was shifting back and forth within the cylinder as it moved in and out. Needless to say, this was hardly a pleasing thing for Ignatius to find.
"Oh, lovely, just LOVELY! The only thing I've found worse than this was the cylinder head in the right engine that was made out of iron-plated bronze instead of steel--and the only reason that was worse was because I had to fix it while the thing was still RUNNING! I told her I could handle all the casting, I did, but what did she say? 'I don't want to overwork you, Iggy,' that's what! Bah! I've done more work fixing that contractor's buggery than I would have making the parts myself! And it's a good thing I hooked up the engine exhaust to drive a furnace, because if we had to buy all our parts, even I couldn't make this thing fly! Now then...I don't have time to replace it--and the crane we put the rudder assembly in with is long gone anyway. I can't even swing the rudder all the way over to the other side and pull the shaft out of the cylinder, because it doesn't swing that far. So I have to fix it in situ somehow, or at least find a workaround. Hmm."
Ignatius pulled a set of calipers from his belt and checked the dimensions of the shaft, the cylinder, and the gap in between. He knew every correct measurement on The Scalawag by heart, but the first step to solving any engineering problem is gathering data, and if he neglected to do it now, it would come back to bite him later.
"Outside diameter 8.2521, inside diameter 7.5005, both within tolerance--but .650 larger than specification. Shaft diameter 6.8503, perfectly on spec--which, of course, is because I made it myself. Ho hum, just another day at the office. So. Couple of long rubber pieces to fill the gap, cut a washer in half and weld it on to hold them in. Ought to work. Have to drain off some of the h-fluid 'cause there won't be as much room for it--above-optimal pressure with same amount. Let's go see what we've got lying around in the way of spare gaskets. And where's the acetylene bottle got to?"
Fortunately, production of the parts was simple once Ignatius found a rubber hose with fortuitously desirable dimensions; all he had to do was cut it in half with his knife. A search of the parts strewn around his workbench yielded an 8.25 inch washer; they were common, as that diameter was standard for a lot of the larger mechanisms. Having a single scale for an entire design project made things a lot simpler to maintain. As he slid the rubber pieces into the cylinder and welded his makeshift endcap into place, he remembered The Scalawag's namesake.
"Now, there was a genius! I met him at HMU, although, of course, they'd already ostracized him by that time and he wasn't a professor anymore. He used to wander into the machine shops. Most of the students just thought he was some bum, but after he helped me figure out why my bifurcated reciprocating crankshaft mechanism was throwing metal shavings so hard that they stuck in the door, I asked him who he was. I couldn't believe it! Carlotta's got her own reasons for going out--he was her father, after all--but I want to know what happened too. I had so much left to learn from him! There, that ought to do it. Now, to drain off some of the h-fluid... As for her, all I have to say is, if she ever tries to buy a part that I could have made again, I'm going to drain all her blood out and use it as lubricant. NOBODY's ever going to abuse you like that nitwit Mowen did by putting these parts in you. You hear me? NOBODY."
Ignatius slid over to the end of the cylinder, opened the adjustment valve, and drained out some of the fluid into a puddle on the deck, then shut the valve and went to the secondary control set, hooked onto the cables that ran down from the captain's wheel up above. He turned them from side to side gingerly at first, then with greater force, swinging the great rudder from side to side.
"Come on, Scalawag, wag your tail for me... Excellent. Yeah. I'm good. So are you. Good girl, smooth as silk. Carlotta's gonna love you. ...Oh, crap!"
He smacked himself on the forehead and swore again when he bruised his hand on his helmet. Tearing the device off and tossing it onto his workbench, Ignatius tore up the stairs to the deck, head swiveling as he looked for Carlotta--an hour and a quarter after she was supposed to arrive.
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