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I was a little nervous about doing the cowl,
but as I went along I either stopped getting nervous, or just stopped
caring, I don't know which... In any event, I am happy with the
results, although not perfect, I am happy... I started by fitting the
prop and spinner. Then I installed the fuse top skin and baggage
door to ensure the spacing would all be correct when I installed the cowl.
Then I installed the hinges as per the plans... Now I was ready to
start on the cowl itself...
I measured 2" back from the firewall and drew a reference line on the
skin for use in determining where to trim the cowl, then I laid the cowl
on the fuse and prop extension... I used a block of wood to
hold the front of the cowl up where I thought it should be, and used a
1/4" spacer to hold it back from the spinner as per the instruction
manual. In hind sight I think I would use an 1/8" spacer instead of
1/4" because my gap ended up slightly wider than the 1/4", but it doesn't
look bad... I then used the reference line on the fuse to mark where
to trim the cowl. The first few cuts were scary, but after a while
it got better. Just remember to cut things long and work your way
in. I ended up taking to big a cut a couple times and now I have
some gaps to fix. But by the time I got to trimming where the top
and bottom cowls meet, I was right on with the cutting... Once I had
the top trimmed to my satisfaction, I put it back on the fuse where I
wanted it and drilled it to the hinges along the top of the firewall.
My rivets will be about 1 1/8" apart throughout the cowl installation...
I have a trike so I had to cut a 1 1/8" slot in the bottom of the cowl
to accommodate the nose gear. The plans didn't say how far back to
cut the slot, but mine ended up right at 12". Once I could get the
cowl on all the way, I used a strap to hold it in place to see how it
fit... Not too bad, but the front needed a little work. So I
took both cowls back off and went to work on the front. I had to
trim off some of the prop opening flange on the bottom or the hole would
have been oblong. Then I used a file and my Dremel with a small
grinding stone to clean up both cowls where they come together at the prop
hole flange to make them fit perfectly, and marked where the holes would
go for the nutplates and screws that will be installed to hold it all
together... Then I did some trimming on both cowls at the outsides
where they will meet (outside edges of the inlets) so they would meet up
flush.
Next I clecoed the top cowl back on and used the strap again to hold
the bottom cowl on. Once I had the front fitting exactly how I
wanted, I drilled two of the 3 holes on each side of the prop hole flange
to hold it in place where it should be. Then I went to the outsides
of the inlets and worked those until they fit perfectly. Then I made
those little aluminum thingys that you put on the outside of the inlets to
hold them and the hinge pin in place, and drilled and clecoed them on to
hold the sides in place too. My thinking was that I wanted the front
to be exactly where I wanted it before I positioned, cut, and drilled the
bottom cowl...
NOTE: I have not done any trimming of the sides where the two
cowls meet and the bottom cowl is still overlapping the top cowl by about
2", except for right at the front where I trimmed them to meet at the
inlets...
Now that I have everything where I wanted it, I marked where the bottom
cowl needed to be cut, took it back off, and made the cuts... I got
lucky and the first cut was right on... I used an 18" body sanding
block to clean and level the cuts and then put it back on the plane.
It fit great, so I clecoed the front back together, and started drilling
the bottom cowl to it's hinges... Be careful when drilling the
bottom corners that you don't push or pull them so far up that they do not
conform to the bottom of the fuse. There is no support right in the
corner and you can mess up right there, ask me how I know...
Once I had the bottom cowl drilled to it's hinges, it was time to mark
and cut the sides to meet in the middle... I used a light in the
cowl to mark where I needed to cut and then took it back off and
made the cuts... While I had the cowls off I also drilled and
clecoed the hinge to the top cowl... Then it was back on with
everything again to check, then back off for final tweaking and sanding,
then back on for drilling. I did use a strap to hold it in place
while I was drilling, but it wasn't that hard to hold it all in place...
The right side is off just a hair, which will be ok because you will need
a gap for paint, but the left side is perfect all the way down, and I will
have to use the sanding block to open that gap up to allow for paint
before I do paint.
That's as far as I got in two days this last weekend. I still
need to do some shimming, and filing of the hinges on the top curve of the
firewall before I can finish. I plane to use the excess cowl pieces
for shims and glass them onto the inside of the cowls and will use
Pro-Seal to bond the cowls to the hinges before riveting... |
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