Week 238 - Cowling Part 13

Hours to date: 2300.5

Part 13 - but not unlucky for me.

Holy Cowl - we seem to have a cowling now!

Lots of air bubbles to fix up but I knew this was going to be the case when I screwed up the layup somewhat.

Plenty of photos this week, so I'll let them do the talking for me.

Ali piano hinges for the sides of the cowl

Extruded type - rather than folded round metal as usual. You must use this type on a cowl.

Stitching together the two halves of the cowl - one side at a time.

Seat belt extension all done.

Tail plane extra securing mod - more about this in another post.

Remember to cover your seat belt with a plastic bag in the middle before bonding on the fuse lower half or the belt will get stuck in place with the micro.

Six months work to get to this point. Cowl finally out of the mold - blue tinge is from the PVA release film. Lots of air bubbles to fix!

Doesn't look too bad. Now figuring out where to part the cowl using a piece of string here.

More figuring out with string for the parting of the top half of the cowl.

Test piece with a Tinnerman washer system - this is how I will fix the cowl at the front and back.

Another test piece with various rivets and a fixing plate for the Tinnerman washers.

Using the mold to steady it while I cut the parting line. This mold has its benefits ya know!

Pre-drilling the hinge - actually didn't need one hole every inch - every 2 inches is enough.

Using a metre long metal ruler as a straight edge for the cut of the parting line for the hinge.

Hinge clamped into place ready for drilling and riveting.

Using Clecos to hold it in place as we go.

End result is a flush riveted join - will most likely close up the gap a little bit with flock.

Lets try this for size...

Some more trimming and fitting to do at the front here. Metal inlets will be bonded to the cowl.

Looking pretty sleek I'd say.

This shows how much exit volume I have - rather generous. I hope this works!